Game controllers and console housing are typically made with injection molding as it provides cost-effective manufacturing in large batches. The precision and finish of plastic molding deliver the desired aesthetic and functionalities.
PS5, Nintendo, Xbox, Logitech F310, . 8BitDo Pro and other various controllers use molding in their manufacturing. What if you can make custom game controllers with injection molding? Whether you are a hobbyist, startup, or gaming company, this process can mold complex controllers with multiple buttons and other features.
This article will elaborate on what is a custom game controller, what are the game controller parts, and why they use injection molding.
Let’s get started!
What Are the Game Controller Parts?
Game controller parts
The parts of a game controller can be divided into two categories: internal and external. The internal components are PCB, sensors, wireless module, USB ports, and battery. On the other hand, housing, buttons, analog sticks, and grip fall under external, where comes the role of injection molding.
Family mold for game controller
A family mold can mold all necessary game component molds in a single cycle, whereas multiple molds can be used to produce different elements independently and assemble them later.
The following are the key parts of a game controller;
- Housing
Game controller housing
It is the outer case of a controller that protects the internal workings while giving an ergonomic feel to the user. It is made mostly of hard plastic like ABS and HDPE, shaped into contours and textured for comfortable playing. With the custom game controller, you can make changeable faceplates or color schemes.
- Face Buttons
The face buttons are big buttons on the right side of the controller and are usually marked as A, B, X, and Y (or variations such as Circle, Triangle, Square, and X on PlayStation). They usually perform basic tasks by the character in the game, like jumping, attacking, or interacting in general.
- Directional Pad (D-pad)
Gamepad D
This is a cross-shaped button mostly found on the left side of the controller. It gives directional input for events like controlling the movements of the characters or moving through the game menus. Most important is that a gamer can have exact shot control on retro or 2D games. Subsequently, modern controllers might now come with D-pads that pivot when changing directions for a smooth directional transition.
- Analog Sticks
Analog stick
Analog sticks are thumb-operated joystick-style inputs that are capable of 360-degree directional input. Most controllers have a pair of sticks, one meant for movement and the other for camera or aiming. Moreover, these are usually concave or have some texture on top to enhance the grip of the thumb during extreme game operations.
- Shoulder Buttons and Triggers
These are also called L1/R1 or LB/RB and trigger L2/R2 or LT/RT buttons, providing additional input options. Shoulder buttons are often used for quicker actions, such as switching weapons. Next, triggers are usually analog and allow variable input, such as acceleration in racing games.
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Why Use Injection Molding to Make Custom Game Controllers?
Custom gaming controllers
First, injection molding is highly feasible for mass production, both technically and economically. Once the mold is made based on a custom design, up to millions of cycles can be run with consistent quality. For innovative designs, rapid injection molding allows product developers to make a few batches cost-effectively and refine them before full-scale manufacturing.
You can achieve tolerance as precise as ±0.02 mm. So, it facilitates the perfect fitting of internal components during assembly. Tight precision also helps to make the design more compact.
Materials Used in Injection Molding of Gaming Controllers
Injection molding materials
Sturdy thermoplastics are the common choices for game controllers; these lightweight materials are easily moldable, can be used for complex enclosures, and are lightweight.
Acrylonitrile Butadiene Styrene (or ABS):
ABS Thermoplastics rank first-most in game controller housings with excellent properties that balance impact resistance, durability, and ease of molding. It offers a smooth finish that is good for painting or texturing. For instance, most of the PS4 DualShock shell is made of ABS material.
Polycarbonate (PC):
Polycarbonate has a solid reputation for excellent impact strength combined with transparency, making it perfect for controllers with a rich & unique look. Subsequently, it holds under impact but does not shatter.
Example: controllers from the Xbox’s “Phantom” series include polycarbonate within their upper casing.
Polycarbonate/ABS Blend (PC/ABS):
It combines the toughness and heat resistance of polycarbonate to give ABS flexibility during processing. This combination is designed for optimum performance in controllers precisely molded for high toughness. It also promotes abrasion resistance to ensure a long life.
Example: PC/ABS is the blend making up the outer jacket of Xbox Series X controllers.
Thermoplastic elastomers (TPE):
The controller surface requires a certain softness and flexibility along with a non-slippery texture, including in the grips and triggers; TPE provides all these assurances for experience during prolonged sessions of gaming with added comfort. For example, TPE is included in the Nintendo Switch Pro controller for the grips’ texture.
Nylon (Polyamide):
Nylon is known for its superior properties of wear resistance. Thus, these attributes are more beneficial for components that have a higher risk of repetitive wear. This quality makes it an excellent choice for the joystick mechanisms and triggers.
Benefits of Injection Molding in Game Controller Manufacturing
Often designers and manufacturers consider plastic molding as a cost-beneficial method to produce controllers in mass volumes, but it has the capability to make high-end and durable consoles.
Let’s look at some key benefits;
Uniform Precision
A single mold is used to make hundreds of thousands of identical items, it allows to make controllers with consistent dimensional accuracy and quality. Consequently, this precision reduces the % of defective items in production.
Depending on the material type & design complexity, tolerances in injection molding are ±0.025 to ±0.5for linear dimensions, ±0.05 to ±0.2 mm for holes, and ±0.1 to ±0.3 mm for contours for irregular profiles.
Production Speed and Efficiency
The fast production cycles of injection molding speed up production. Next, a single setup of mold in the machine can be run for thousands of cycles, reducing downtime and improving production efficiency.
Diverse Choice of Materials
ABS, PC, PP, Nylon, rubbers, and other serval material options are available to mold the game controller parts. This diversity helps to find the best-fit options based on design and performance requirements.
Aesthetic Finishes
A good quality mold with a fine cavity wall can provide a quality surface for molded items; even textured or engraved designs can be achieved with the right mold designs. Furthermore, the custom controllers can be polished or painted for a personalized appearance.
Low-cost Without Sacrificing Quality
Molding custom controllers is affordable as a mold is reusable for multiple batches, even soft aluminum tooling. It reduces the cost as per/part tooling costs spread over a large number of cycles. However, the overall quality is not compromised.
Other Injection Molding Examples in the Gaming Industry
Besides game controllers, there are many other injection molding applications in the gaming industry;
- Console Housings: Durable and stylish outer shells for gaming consoles.
- VR Headsets: Lightweight and precise plastic parts for comfort and functionality.
- Controller Grips: Ergonomic designs with textured finishes for better handling.
- Memory Card Cases: Compact, protective storage for game data.
- Cable Organizers: Efficient management tools for controller and accessory cables.
“You can read about its applications in the toy industry as well in this injection molding lego article, including how they are made and benefits.”
Mold Making for Custom Gaming Controllers
Mold for game controller housing
To make a gaming controller unique and personalized, first create a mold. This process typically begins with designing the desired part, such as buttons or shells, followed by crafting a mold using materials like silicone or hard tooling like stainless steel and aluminum. Meanwhile, CNC machining, EDM, laser cutting, and other precise techniques are used in hard tooling for controller molding.
As for the casting, fill the prepared mold with molten material to shape the desired custom part. This method always renders results above expectations and is best for delivering unique colors, graphics, or textures.
- Choose High-Quality Materials
- Create Accurate 3D Models of desired parts
- Prepare molds before injection, such as cleaning and applying releasing agent,
- Experiment with customization
- Perform test runs for overall compatibility
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Summing Up
Overall, using injection molding for game custom game controllers throughout the product development cycles offers accuracy, finish, cost-benefit, and freedom for new innovations. As major gaming console companies use this technology, you can also leverage it for custom projects.
If you have your design ready, go with injection molding services China. The extensive manufacturing network and technical expertise deliver accurate results at affordable rates. The online manufacturers can work for you, from mold creation to finishing of molded parts.
FAQs
What are some examples of injection molding game controllers?
Examples of injection-molded controllers are the Xbox Series, Dualsense, X controller, and Nintendo Switch Pro. These involve molded plastic enclosures that are lightweight, comfortable, and aesthetically pleasing.
Do custom game controllers work on PC?
Yes! They are compatible with PCs and support common standards like Bluetooth, USB, or XInput/DirectInput.
What does a custom controller do?
A customized controller offers features like re-mappable buttons, adjustable triggers, and personalized aesthetics to enhance the gaming experience.
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