Fillet count?

• A. Fewer
• B. More
• C. Several
• D. None

Answer: (A)

Keep fillet count as low as possible while still meeting the design’s functional and assembly requirements. Each fillet adds a feature to manufacture, inspect, and deburr, which increases machining time, setup changes, and potential interference with mating parts or tight tolerances. By using only the necessary fillets, you simplify the manufacturing process, reduce cost, and minimize risk, while still providing the benefits of fillets where they genuinely improve strength, flow, or fit. So the best approach is to have fewer fillets.