A method for repairing a defect in a vehicle exterior body surface is provided that includes a scan data set being generated that corresponds to the dimensional surface boundaries of the defect. A manufacturing data set is created for an object at least in part complementary to the defect from the scan data. The object is formed from the manufacturing data set with a layered manufacturing device. The object is joined to the defect to repair the vehicle exterior body surface. An object is also provided formed of a thermoplastic or a UV cured polymer with a shape that is at least at least in part complementary to a defect vehicle exterior body surface. The object having a void therein with the shape configured to receive an insert or a fastener therein.