Just now, a friend helped make comparisons with 2 commercial apps. Attachment is: 1. Benchmark file STEP file, without fillet (exported from .FCStd file of above post) fsc_2020-06-24_193143.jpg 2. Frozen view of FreeCAD usage: unzip file >FreeCAD >menu >View >Freeze display >Load views Anyone who h...

Here, FreeCAD Bevel's algo appears obviously weaker than commercial apps. Just now, a friend helped make comparisons with 2 commercial apps. Case 1. co-vertex cut app 1 (below) fsc_2020-06-24_184358.jpg fsc_2020-06-24_191057.jpg app 2 (below) fsc_2020-06-24_184428.jpg fsc_2020-06-24_191137.jpg Case...

I made a simpified model with PartWB Bevel, based on concept of OP. Co-vertex cut =>Asymmetric Bevel joint =>Weird patch at intersection. The result is better than OP, for it formed a valid solid. fsc_2020-06-24_182940.jpg fsc_2020-06-24_183011.jpg fsc_2020-06-24_183044.jpg Here, FreeCAD Bevel's alg...

Guess from above digging. 1. OP's coplanar cut caused 3 edges intersected in asymmetric way. (co-vertex is direct culprit here.) fsc_2020-06-24_164250b.jpg fsc_2020-06-24_164608b.jpg 2. Bevel caused a 6.59um gap between asymmetric edges. https://forum.freecadweb.org/download/file.php?id=118975 3. Th...

Further digging. 1. PartWB >Simple copy, convert OP's model (before bevel) into a Part solid. 2. PartWB >Bevel, radius = 1mm. Got a bad geometry. 3. fix above geometry with @wandererfan's ShapeFix macro. 4. Got a better result, but still CheckGeometry invalid solid. 5. Zoom and observe. fsc_2020-06-...

Summary: PartWB, Bevel/Chamfer/Boolean operation on non-compound solid/s always create a compound outside solid, while the intended result should be solid only. I donnot know wether this is design intent or a bug. Reproduce: 1. Start Freecad, switch to PartWB. 2. Create a cube primitive. 3. Select a...

should be fixed by 73f086f73d . This bug is solved in latest build. Both for 3D Offset and Thickness. Both for Bevel and Chamfer. Also, CheckGeometry after Bevel/Chamfer is error-free. fsc_2020-06-22_133053.jpg fsc_2020-06-22_133157.jpg Thank you, guru and everyone invioled. OS: Windows 10 (10.0) W...

keithsloan52 wrote: ↑Sun Jun 21, 2020 2:49 pm
Would be best if you posted as Bug see https://wiki.freecadweb.org/Tracker

Reported now.

TheMarkster wrote: ↑Sun Jun 21, 2020 5:10 pm I'm surprised it worked at all with the inner wire in the sketch.

So, it seems fixable?

TheMarkster wrote: ↑Sun Jun 21, 2020 4:55 pm If Face = False I get the error, otherwise no error.

Thank your confirmation.