Full Round Fillet in SOLIDWORKS

Article by Caleb Overcash updated April 17, 2023


The Full Round Fillet in SOLIDWORKS is one of four main fillet types available to users. Those four options are Constant Size Fillet, Variable Size Fillet, Face Fillet, and Full Round Fillet. The Full Round Fillet option is unique in the fact that it only requires three separate face selections to create a fillet feature, without any numeric input necessary from the user. In this article, we will explore where to find this fillet option, how to create it, and a few tips and tricks on where best to use it.

Full Round Fillets in SOLIDWORKS

When creating a 3D model, designs will often call for a specified radius to be applied on the edges of the part. Sometimes, this specified radius is a Full Round. What exactly is a Full Round Fillet? A Full Round Fillet is a type of fillet that is created by selecting three adjacent faces. Two outer faces to control the thickness, and one top face controls the height. In this selection set, no material is added to the model. Instead, SOLIDWORKS calculates a tangency between the three faces selected and then trims away the execs to create a smooth tangent fillet between the three faces. To help visualize this, the image below is provided. The arrows on the left and right show the outer face selections, while the top arrow highlights the top bounding face that controls the height of the fillet feature. The magenta outline depicts the material that is to be trimmed away to create the full round fillet feature on the model displayed in the image below.

Full round fillet tool

SOLIDWORKS Fillet tool

Creating this full round fillet is a very simple process that begins by activating the Fillet tool on the command manager. Once active, the full-round option can now be selected. Next, the face selections must be made. As shown in the image, three selection boxes are now displayed in the property manager. These selection boxes are color-coded, which allows for the selected faces to have the corresponding color temporarily applied for easy visual reference. Note, that the faces must be adjacently connected to one another for the full round fillet to succeed. Now that the selections have been made, a preview is displayed in the graphics area for review. In this example, a total of three faces is all that was selected to create the fillet feature; this is attainable because all connecting faces to the selections are tangent; which is a requirement for this specific example to succeed. This is also possible due to the Tangent Propagation option, which extends the fillet to all faces tangent to the selections.

The full round fillet does not always have to be on a continuous tangent edge, it can also be used on a single feature such as a Rib. Below are two examples of how this full-round fillet can be used in different scenarios. The left image shows a simple box with ribs on the interior. In this example, selections were made similarly to the previous model shown, but in this case, the fillet cannot propagate around the rim of the part because the edges are not tangent to each other. Also in this example, the dividing ribs have full round fillets applied; and it should be noted that these were created one at a time. The reason for this is that their face selections, while similar, are not touching so each rib requires its own fillet feature.

The image shows a model that was extruded with a more complex curvature, and the full round fillet is used here as well. To create this feature the same selections, outside and top/center adjacent faces, were made; and since the tangent propagation is selected AND the edges are tangent between all side faces, the fillet follows the entire length of the model. So, as we can see the Full Round Fillet is a very easy feature to apply, especially after understanding the rules associated with its success. This option is also very beneficial in that no calculations need to be made by the user. If the selections change dimensionally, SOLIDWORKS does the math and updates the full round fillet automatically, making it an intelligent, flexible, and versatile tool to have in your toolbox.

View the on-demand webinar >> TriMech Tips & Tricks for SOLIDWORKS Fillets

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Caleb Overcash