Mortek, just studying your part in the other thread a bit, about filletting, I too have troubles with that. I can envision the problem with the spots where the 1/8 and 3/8 fillets might meet. Also, I suppose the boss is just sitting on top of a large flat surface?
I've got a theory right now that you need to have intersecting surfaces, but not overlapping surfaces, because the overlap cannot trim properly for the fillet. This would involve breaking up your large flat surface into chunks that mate with a single given surface of the boss, kind of like equalizing chains before skinning in Bobcad.
In a situation I was working on, I could not draw the fillets, but I could cut them okay with a ballnose tool, so I didn't sweat the details of filletting. It looked right in the simulation, that's all I needed to see.
For your custom 2d path, you would create a boundary that represents an offset around your boss as an island. Then, when you create the 2d path, you would use this boundary as an island and the outer perimeter boundary as the outside of your pocket. Then follow the procedure I outlined in the post above.
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