Automobile Rusted Panel Cover

thingiverse

I'm stumped for a better name, so if you come across this and can think of something more fitting, send me a message. This is a 3D Printed "patch" I created to cover up the Gas Cap on my Ford Ranger. The metal gas door/flap had rusted through the bottom left corner. I removed the damaged section and designed a creative aesthetically pleasing replacement using Tinkercad, which can be edited online at https://www.tinkercad.com/things/9hUeQfT3ng9. I printed several versions of this patch with different materials to see what worked best. The first ones were made with a variety of materials, but the final one I chose was printed with clear HT-PLA from Proto-Pasta. To add extra durability, I applied multiple coats of UV-clear coat using Rustoleum. The patch has been in place since around April 2018 and it's still going strong despite being exposed to harsh winter conditions in Wisconsin. So far, it hasn't cracked or worn off. However, the gold highlights have dulled slightly due to road grime buildup.