Laser-carved Dredd 3D badge -- work in progress, need advice on finishing wood

horseflesh

New Member
I'm working on a replica of the Judge badge from the Dredd 3D (2012). I decided to post here instead of the Dredd subforum because I'm more looking for help right now than showing off. :)

The badge was made with a laser cutter. Everywhere the laser touches leaves some texture, and in the deepest places where the laser has removed the most material, there is a really rough sandy texture. The un-burned high points still have wood grain to conceal.

I would like to find the best way to finish laser-carved wood to produce a smooth surface, suitable for painting or making a mold.

Here's my work-in-progress version. This is actually carved from MDF but I think basswood is a better material, as it ablates more easily and produces less gooey residue. This particular piece was sealed with acrylic size, then primed with gesso. I know there has to be a better technique. Any ideas?

badge.png

(bigger image link)

Here's a closeup of carved and (poorly) primed basswood. You can see there is a lot of texture and grain to conceal.

2018-01-02 11_57_32-Photo - Google Photos.png

And this is what it looks like with a base coat. No hiding that this is wood... Not yet.

2018-01-02 12_02_17-Photo - Google Photos.png

Many thanks in advance for any tips you can give me!
 
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