When modelling in Solidworks (or other tree based parametric modellers) there’s a rule of thumb; you should add fillets near the bottom of the feature tree. Unfortunately, this can result in undesirable forms/geometry, especially where diverging surfaces share a common edge. In this case it is better to add a fillet earlier in the feature tree, then make some downstream geometry reference the fillet. In this video I show a couple of simple examples of this issue and ways to get around it.
