Xbox Controller Prototype

Fabrication

We fabricated the controller using a combination of CNC milling, CNC turning and vacuum casting — processes we considered suitable for the complexity, scale and unit quantity of the project.

The body

The main body of the Xbox controller prototype, which comes in two halves so it can be clipped onto either side of a portable device, was CNC machined from ABS.

To achieve a professional-quality finish, we then sanded and painted the two parts, finally adding the logos and “XBOX CLOUD” text using silk-screen printing.

Back plate

The controller is designed to be as ergonomic as possible, so the rear side of the controller features a rubberized back plate. For this section, we used the process of vacuum casting before adding aesthetic details using silk-screen printing.

Buttons and flippers

The buttons and flippers will function as the controller’s inputs, and for these small components we again turned to CNC machining. Unlike with the main body, we used a high-gloss paint for the buttons and flippers, resulting in an almost metallic finish.

For the flippers, we also added a grippe rubber like coating by over molding the plastic components with vacuum casting.

Connector

The Xbox controller concept incorporates charging pins. For these components, we used CNC turning to fabricate the rounded pins from brass.

Delivery

We sent the finished prototype to client not long after he sent us his digital files, drawings and material requirements.

Just as we hoped, the designer was extremely happy with the physical version of his creation.

“The buttons feel exactly the way they should, and the joystick is as inviting as the real deal,” he gave feedback, adding that the controller looks and feels “like a product right off the shelf.”

It’s not the first home entertainment project we’ve completed, and it certainly won’t be the last. Get in touch for a fast quote on your prototype.