Now that the OSWatch parts functionally fit together, it's time to move into some detailing work. The first thing to look for are any dimples, or indented imperfections on the outside of the shell. sometimes corners or other parts may have small gaps as well. Use superglue to fill them in. If you are printing with clear filament, the superglue blends in really well, and once sanded and sprayed with a gloss, becomes almost indistinguishable.
Once you have filled in any dimples or indents, let it dry. Sanding superglue before it is dry is a very bad idea. This may take up to 30 minutes depending on how many layers of super glue you used. Once it's dry, re-assemble the shell, screwing it in tightly. Now use the rough sandpaper on all sides gently. Sanding PLA can be problematic. It tends to melt slightly and flake instead of smoothing. You can also use a dremmel rough sanding attachment, but be careful. The fast spinning wheel can generate enough heat to warp the plastic. Finally take apart the shell and sand the joining parts of the top and bottom. You want both to be as smooth as possible.
Now, your parts should look similar to the image below. Now, move to the fine sandpaper. I have found that using fine sandpaper with PLA works fairly well. Don't forget to do all the sanding with the shell of the watch assembled. This will give you the most flush results. You have some aesthetic decisions now. If you plan to paint the shell, you can be more relaxed with sanding. if you do not want to, then you may with to sand more. In the end, it's up to you. Also, if you are not doing a clear filament, I would strongly recommend painting as the superglue will stand out more than you may like.
Also, if you are printing in a solid color. You will need to either drill small holes for the two LEDs on the top face, or cut out a section and replace it with clear plastic. I don't have a dual filament extruder, so, I have to assemble it, but if you have a dual extruder, you could add the opaque part in the top lid as you see fit.
Now let's paint and polish the parts.
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Updated May 16, 2014