SOLIDWORKS Design & Help

Try unchecking “tangent” and then select one edge at a time, or try using the face option or conoc option. If that doesn’t work then you may have to try variable or reducing the radius.

hope this helps.

If it didn't work, just make a swept-cut along the edge of your model, where the profile will look like this:

It may be impossible to say for sure without looking at the model, but I'd place my money on one or more tiny segments near the selected edge.

Try picking the flat model face which has the blade passing through it. Doing so will affect all of the edges (assuming there are some tiny, invisible ones there).

Also try changing the radius value to a smaller number (1mm) and seeing if it starts to work. a 21mm fillet on the front of a handheld tool seems very large.

As stated above, try a small radius and then work up in size until it fails. Is the protruding blade a separate feature? or is it all one solid. If it is all one solid, the radius maybe struggling to blend into the square edges of the blade. Try blending the handle, then add the blade last.

Face fillet is a lifesaver

You could always surface in the fillet manually as well.

What do you mean by "surface in the fillet"?

Check out some of the techniques shown here:

http://dimontegroup.com/solidworks-world-2014-will-blend/

There may be some newer presentations as well, but this one came up first.

The basic idea is trimming away the sharp edge, they manually building the fillet with surface tools before knitting everything back into a solid.

Amazing techniques.

Thanks for sharing.

what is fillet ? I'm not sure

Filleting = Rounding-off edges

Non-filleted pole (left) and a filleted pole (right):

Split the part in half (best to use cut with surface and select the center plane as surface)

apply the fillet

mirror the bodies

Filet is rounding edges, faces, etc.