kdgrills: "Are the cylinders correct & you need the walls to be tangent to them?" Yes, that is what I'm trying to do.

Photo here of the part using the Solids-Fillet function.

It was reverse engineered from an existing tool using a Faro Arm and Verisurf/Mastercam X4. The final part should look like the photo I've attached here, with a constant radius fillet, but it should have the same angle of its fillet as the 4 cylinders in the file I attached. When I do a Solid-Fillet using the same diameter value as what I captured from the Faro Arm, the angle of the fillet is incorrect, as the actual part fillet bulges out somewhat at the bottom of each fillet, as can be seen on the first photo I attached in my first posting. Hopefully this makes sense. Thanks

Does anyone have any other ideas on how to do this? Mastercam has a feature in Solids-Fillets that does "propagate along tangencies", which sounds like it should do what I want, but I can't figure out how to make it work. I have also tried working with surfaces and trimming them, and the function is not working for me.

Hey, thanks for doing this. It's much closer than what I've been able to get, but it's still not quite perfect, as you can see if you bring the cylinders back in. They master tool I am reverse engineering has a slight bulge at the bottom. See photo.

Can you please save it as an .MCX file for version X4? I cannot open it since it is an MCX5 file. Thanks!

By the way, I have tried trimming surfaces to surfaces, but it doesn't work for me.

Thanks for the replies. These are solids, and the file is attached here. I've tried several different ways to make fillets from the solids, but none of them are capturing the same fillet profile and angle as the cylinders, which means that the profile is wrong in the corners. MASTERCAM SOLID FILLET PROBLEM.MCX

I am trying to reverse engineer a part that has 4 complex fillets. I need to create 4 fillets in this solid model that follow the exact profile and angle of these 4 cylinders shown in the photo. Is there any way to do this? I am running Verisurf/Mastercam X4. Thanks