Smooth edges on a custom object

Question

I have a custom made object (no simple standard mesh, but nothing complex, see below) and lost a lot of time trying to make the edges smooth. I tried the bevel modifier, sub surf modifier and bevel by select certain edges (ctrl+B). None of them worked fast and reliable.

• Selecting them edge by edge (very time consuming) left me with problems where two different bevels where meeting.
• the bevel modifier did no work as expected every time
• sub surf modifier just created a very distorted mesh.

This is my mesh (viewed from different angles):

I just want all the edges to be smooth. No big deal...I thought :) I only succeeded on the front ones.

Answer 1

The point is to imagine the several angles your mesh will have to be bent.

It can be composed of an initial shape and 3 modifiers : mirror, simple deform and subsurface.

Here, there is a final curve : the "U" general shape.

But before that the mesh can be flat. Here the mesh before using the two final modifier (simple deform and subsurface) :

The main point is to use quad everywhere so that :

• Edges are in the good position to be bend to the "U"
• Subsurface modifier works well

Notice the selected line on the screen capture : it is here to preserve the outer edge and avoid the subsurf to deform it too much.

As you want to print it, you may want a "lot" of subdivision.

Here is the modifiers stack :

Here is the blend file