Hi PM2.5:
Those fillets will increase the cost of making the parts substantially, especially if you need them to be good looking or accurate.
The fillets on the outsides of the block will require two setups to complete the part, and to make them accurately will require that the second setup be accurate with respect to the location and orientation of the part.
By "accurate" I mean better than 0.0005" for the second side setup or else that underside fillet will look like a pig's breakfast, whether you surface mill it with a ball cutter or use a corner rounding cutter.
A chamfer there is much more forgiving, so an ordinary vise with a stop will be more than adequate.
On the cavity side, there are fillets you cannot mill as modeled, so if you NEED it to be exactly as modeled you have to sinker EDM it, and if you need it to be pretty good you can surface mill it with a tiny ball cutter and then pick out the corners with a file under the scope.
That makes it a five hundred dollar part instead of a twenty dollar part.
If you really don't give a damn, and all you need is for no one to cut up their hands when they handle it, you can just throw it in the tumbler or edge break it with a file.
Now it's a twenty dollar part again.
Cheers
Marcus
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