Best Of

If it is mirrored: Roll back and make the fillet before the mirror. Easy. :0)

You should be able to get this working, and I suspect an units mismatch. For example, if #frame_material_width is a length not a number then your formula would result in an area because you multiply it by "in" at the end. You could check by trying your exact same formula in a Variable feature set to "Any", which will allow you to run any expression that evaluates to something, even if it's not the kind of thing you wanted (i.e. area, not length). If that fails too, then you know it's a syntax error, not a units mismatch. This kind of thing is why I actually prefer to always keep the units with any values I'm working with instead of working with raw numbers and adding units after. It's a bit more cumbersome, but when done right it should let you know when you've made an error.

Btw you could declare all of the width's in a single map variable if you want. Something like:

#widthMap = {

"2x4" : 3.5 * inch,

"2x6" : 5.5 * inch,

};

Then later you can get them like #widthMap["2x4"]

If the asm and the part studio are in the same document, no. (but you can if you want). You can insert the workspace of the part, and then the asm will automatically update if the part changes, without you doing anything. If it's in separate document, yes, a version of the document the part lives in is mandatory.