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Fillet radii are extremely important but are often overlooked by component designers.


  • To avoid high stress concentrations in the component and the die, fillet radii of the appropriate size must be used in all internal and external component edges
  • The exception to this rule is where the feature lands on the parting line of the tool
  • An important aspect of fillet radii is that it assists in filling the part die
  • There is an optimum size of fillet where structural parts are concerned
  • Although increasing the fillet radii size will generally decrease the stress concentration at the bottom of a rib, eventually the mass of material added by the fillet will induce shrinkage porosity in that area
  • Designers should also note that fillets applied perpendicular to the parting line of the tool require draft

Designs that are less desirable and should be avoided