Anyone else mixing chamfers and fillets on edges? Curious how you handle it

I'm firmly in the blended edge camp for anything that touches skin. I made a set of drawer pulls last year and the first version had plain 45 degree chamfers. They printed fine but the edge felt like a dull knife after a week of grabbing them. Redid the ends with a curve leading into the flat and it was night and day for comfort. The layer lines do soften the highlight a bit, but the reflection still rolls across the surface instead of snapping, and that reads even in matte PETG.

My workflow is less fancy than most people here though. I model in Fusion and I stopped trying to stack a chamfer and a fillet as seperate features. I just sketch the profile I want on the end face and do a sweep or press pull along the edge. It survives edits way better becasue the profile lives in one sketch instead of two dependent features that fight each other when the base geometry moves.

Where I totally agree with you is functional parts. Every bracket and spacer I print gets the plain flat cut, sometimes not even that. The curve buys nothing when the part is hidden inside a machine and a steeper face actually helps with first layer squish on edges that touch the bed.

One honest confession: I still leave sharp edges on the inside corners of enclosures where nobody will ever see or feel them. Life is too short to dress up geometry that lives behind a wall.

I land on the plain chamfer side, mostly because of how my parts actually get used. I print a lot of jigs, mounts, and shop stuff for my garage, and anything with a curve on the edge tends to come out with little artifacts where the overhang starts. A flat 45 on my Ender 3 just comes out cleaner, first try, every time. The blended look is nice but I can't justify the failed prints to get there.

The other thing is parametric robustness. Stacking a fillet on top of a chamfer in Fusion 360 breaks on me constantly when I go back and change a dimension. So now if I really want that soft feel, I just draw the whole profile in the sketch, one line with an arc, and extrude it. The sketch survives edits way better than two stacked features ever did. For anything people actually hold, I get the appeal, and the drawer pull example makes sense. But for the ninety percent of my prints that nobody touches, sharp and flat wins on effort alone.

My two cents from the parametric side: if your CAD has a proper variable-radius fillet, you can often get this same effect by running a small fillet on the chamfered edge itself, so the tool treats it as one feature instead of two. The trick that took me embarrassingly long to learn is ordering. Chamfer first, then fillet the two new edges the chamfer creates, and if the model regenerates badly you swap the order in the feature tree. On boxes with lots of edges meeting at corners it still chokes sometimes, but on a simple handle or a top edge it regenerates cleanly every time I drag a dimension. Has anyone tried this on curved edges though? Mine tends to fail on fillets that meet an arc.

Totally with the sketch-and-sweep approach, that's how I do it too. I made a few tool handles for the shop last month and putting the whole profile in one sketch meant I coud tweak the curve once and it propagated down the whole edge. Before that I tried stacking features and every time I changed the handle length the fillet would error out and I'd have to redo it. Never going back. One thing I noticed though, on the flat faces around the curve the bed adhesion got worse, so I added a small brim just on those parts and that solved it.