Fillet Gauge

by TnaTmr, published

Fillet Gauge by TnaTmr Dec 8, 2015

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Fusion 360

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Update: I have now made an Inch version for those who don't use metric! You can find it in the remixes section.

The other day I was watching Noe Ruiz from Adafruit's Layer by Layer, in which he was designing a case for the Apple TV remote. And when he was trying to measure the fillet he couldn't get an exact measure so he had to guess. And I've had this issue as well when designing stuff with a curve. Then I thought: how can I solve that? Well I have a printer, and a computer, so why not make something on my own. I tried to do something simple, both to design and print. With this, you can measure most curves on objects, like a phone's corner for example. I think this will be quite useful for people that are trying to design something that is to fit an object. Its also very easy to use.

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Simple Black


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How I Designed This

Simple Sketches

For a start, I just made a simple sketch with the fillet sizes 1 to 12 mm. Then I extruded the sketch to a modest 2 mm. Next I added the numbers which I engraved. But then, after printing, the numbers weren't so clear, so I extruded them which worked heaps better.




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Project: Design Tips

-Learn new designing tips
-Design objects from a reference that has fillets
-Learn how to design objects that are to fit something with fillets
-Get experience in design softwares like Fusion 360
-Learn new vocabulary such as; fillet, arc, corner and their use in design softwares

-Anyone who is getting started with more advanced modeling softwares and are starting to design objects from a reference and are designing models to fit a specific object with fillets.
-Students in grades 5-10 can use this project to learn new tips in designing more complex objects with fillets from a reference.

-Students will need access to a computer with internet connection and a 3d modeling software
-Since its easier to use, a mouse is recommended
-The students already should be familiar with design softwares and should know how to design simple objects from references
-The students should be in an environment where they can collaborate with each other to try measure the fillets and do some teamwork

-Step 1: Choose an object to refer while designing
-Step 2: Take measurements of the object using calipers and the measurements of the curves using the fillet gauge
-Step 3: Choose something that you are going to design (has to be connected with the object you choose in step 1)
-Step 4: Using simple tools like sketch, extrude, fillet and modify, create the design
-Step 5: 3D Print and share with others

-After all, the students should have:
A 3Dprinted design that can be part of an object,
-And should have learned:
How to design objects with fillets that are made by referring to a physical objects, how to measure fillets, to start doing more complex designs in 3D modeling softwares, new designing tips, and simple commands like sketch extrude fillet and modify.

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i didn't know this tool existed, i always wondered how to measure a curved corner. i used to freehand them. thank you

GEEZ Thanks! Turns out i need more than just calipers ;)

Wow, this looks like it will be super handy, so simple yet so useful. Cheers!

Thanks for the design!

Whenever I make similar ruler type models the numbers (text etc) easily pop off the surface. :/

On mine the numbers didn't adhere at all, just globbed up on the end of my hot end, I ended up adding them with a Sharpie marker. I think it's actually a problem with how Cura reads the STL. I noticed in OctoPrint that the gauge itself previewed fine in the gcode viewer, but what should have been the last couple layers for the numbers actually was being interpreted as a bunch of separate layers.

I sliced with Cura as well. What size nozzle do you use. It might also have something to do with you settings. I can share my Cura profile if you wish.

greater infill, more outlines, and more top layers help with this. Also check your perimeter overlap and perhaps increase it a bit.

Did you have any problems printing this? Also, if you are using Fusion 360 I can tell the size and font I used in this design.

I didn't print this one. I do modeling in Rhino 3D > OBJ > Cura.

Great idea well done this thing i need desperately.

Great little print, very small form factor and prints very quickly and easily. Its also very accurate and is something I've unknowingly needed for a long time. Keep up the good work :)

Thank you. Pleased you liked it :)

This is brilliant. However, I found that these are actually made as a real world product called Radius Gauges.

Probably gonna buy a set on Amazon.

Good work.

Much appreciated, came up stumped when I wanted to design a phone case for a phone with a lot of rounded curves both seen from the front, side and top/bottom and tried in vain to use my calipers, printing one of these atm.

Might want to turn the .stl to make it the right orientation for printing btw, yes we can do it ourselves but making tens-hundres-thousands or people do that step instead of you doing it once is a bit... silly imo.

Tebrik ediyorum seni.. Gerçektek çok işe yarar bir klavuz hazırlamışsın, biz tasarımcılar için bulunmaz bir nimet değerinde olduğunu düşünüyorum. Sana önerim bu tasarımını kredi kartı ölçülerine çekip daha portatif, daha toplu bir hale getirmen bu sayede cüzdanda taşınabileceğinden çok daha efektif bir kullanımı olacaktır.

Öneri için teşekkürler, iyi bir fikir ve hemen üzerinde çalışmaya başlayacağım :D

Your gauge looks like it's very well made and handy for designers as well.
Not to nitpick T, but when I had mechanical drafting way back when it was T squares and triangles I was taught that an inside radius was a fillet and an outside was a "round". While both are sometimes called fillets, a true fillet serves to strengthen the part and in the case of welding comes naturally with the process.
see -

Keep up the good work

Hey, thanks for pointing this out. As an amateur in these fields it can be difficult at times to know the correct terminology. It never hurts to learn to speak precisely about a subject.

I just use the term fillet because it says it in the Fusion 360 program, but thanks for informing, thats something that I had never heard before, thank you again :D

Hi Tuna,

Thank you so much for designing this! This is really helpful and useful, I'm printing it right now! It's really great to see you taking a problem and solving it with a simple design. I'm going to share it on the Adafruit blog on Thursday and show it on 3D Hangouts :-)

Keep up the great work and remember to keep on'a makin!


Im so happy that you liked the idea. And thank you very much. I always watch your shows on Adafruit so thats where I got the idea anyways, thanks again :) Your designs inspire me for new designs.


This is awesome. i was just taking to my friend about making one of these. Thank you.

Happy to see that you have liked it!

This is the second filet guage I have seen on Thingiverse. Love the idea as I have always wanted to print a case for my phone, but never had the dimensions for any of my "niche" devices.

I am curious though about the 3mm and 5mm curves on either end. Did you just pick the sizes out of the air or is their a specific need for those measurements.

Keep up the good work.

Three and five are a couple of my favorite Fibonacci numbers, too bad it doesn't go to thirteen.
Maybe because some Thingiversers might suffer from triskaidekaphobia.

The 3 and 5 at the ends is for inside curves, which isn't as much seen as an outer fillets, but its just there in case you need it.

My guess is the space was available so why not use it for something useful? Getting ready to print this myself as I was getting ready to design a mount for a small box with curved corners. Wasn't looking forward to the guessing game. :)