Fillet or blend between two non-parallel cylinders

[Dale Grice]

Hi all,

 

I have been struggling or having a senior moment with getting a fillet between these two cylinders. Like rubbing a bead of caulk with your finger between them. Any suggestions?

 

Thanks,

 

Dale

 

 

[SLW210]

Welcome to CADTutor!

 

Can you post the .dwg?

[BIGAL]

Going back a few steps looking at your image if you were to draw the two outside circles in 2D, you can add a fillet arc using Circle TTR you need to trim the new circle and trim the existing two circles add the outer edges and so on add the inner tube circles then extrude the outside  object as a pline. There may be some way to add the correct fillet to a solid beyond my pay grade some one else will jump in.

 

 

[Dale Grice]

Hi,

 

Drawing attached.

 

Dale

CB&Q water tower hoop lugs v2.dwg

[SLW210]

I gave the drawing a look.

 

I am not 100% sure what you are trying to accomplish here, in order to fillet the two cylinders they need to share a common edge(s), the rectangular extrusion you have between them needs to be unioned as far as I know, if that's what you are trying to use, by the way it looks to be two of those.

 

You might have better luck extruding a fillet shape between them and then union that to them.

 

[SLW210]

On 10/31/2026 at 8:56 PM, BIGAL said:

Going back a few steps looking at your image if you were to draw the two outside circles in 2D, you can add a fillet arc using Circle TTR you need to trim the new circle and trim the existing two circles add the outer edges and so on add the inner tube circles then extrude the outside  object as a pline. There may be some way to add the correct fillet to a solid beyond my pay grade some one else will jump in.

 

 

 

The two tubes run at different angles.

[lrm]

Create sections (green) at several points along the object.

Explode the sections then set a UCS to the plane of a section and create offset curves (red) with a distance equal to the desired fillet radius.  I used 0.2. Add a circle of the fillet radus at the intersection of the offset curves and then trim the circle. Create a polyline (yelllow) to form a closed shape that includes the "fillet" arc (cyan).

  

With pedit create closed polylines for the fillet sections then use loft to create the fillet solid.

Union the two solids together.