I was finishing a desktop case for a GTT module and wanted to demonstrate the process.
First I start with a 3D print of our case design. This first photo is after initial application of some Bondo. The specific Bondo product is "Glazing and Spot Putty" which is a one part paste full of VOCs and cancer which requires adequate ventilation. It sticks to the PLA of the print very well, but I do sand it to roughen it up first (and remove high spots).
After application of Bondo, it is sanded on a flat surface. It is important to build up the Bondo against a flat reference. You can not "free sand" until the very final steps. After each sanding, the object is painted with sanding primer. I do this to provide a layer of color for sanding the next coat - when I see the primer exposed, I know that I need to stop sanding. This shows the painted piece.
Next more Bondo is applied.
This is then carefully sanded bit by bit until as much Bondo is removed as possible without sanding beyond the previous layer.
This process is repeated until all the low spots have been filled.
And this is the piece just before the final (or second final) application of sanding primer.
After this, the piece is sanded one last time with very fine (800) sandpaper and painted with color. I should continue this thread and fill in details. Any interest?
Take a load off and chat!
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