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Fillets and Radii

Fillets and radii are generally advantageous to product function as they reduce stresses at the intersection of features. They are also advantageous to the molding process, by eliminating sharp corners that can cause cracking or erosion of mold features, by facilitating the flow of feedstock into the mold, and by assisting in the ejection of the part from the cavity. They may also provide a softening of sharp corners for esthetics and handling. Fillets and radii of 0.4–0.8 mm (0.015–0.030 in.) are generally preferred.