In relation to chamfers and fillets, should parts be designed with or without them?

• A. With
• B. Without
• C. Only on external edges
• D. Only when aesthetic

Answer: (B)

Designing without chamfers and fillets prioritizes simplicity in manufacturing. These features add extra machining steps, tooling, and time, and they complicate tolerance control and inspection. When edges are kept flat and straight, the parts are easier to machine consistently, faster to inspect, and cheaper to produce, with fewer chances for assembly misfit caused by unexpected radii or bevels. Add chamfers or fillets only if there’s a real need for clearance, improved assembly, deburring, or safety. That’s why the best default is to design without them.