Replacement Xbox 360 Joystick/Thumbstick ( + extension)

These are replacement joysticks for xbox 360 controllers. The design is suited for 3D printers and not identical to the original. I have experimented with a few different designs trying to find the more grippy design that is easily printed.

You need to purchase a t8 torx screwdriver( available at amazon or ebay) in order to use this. Disassembly is pretty straight forward and only require removal of 7 screws and a full replacement can be done within 5 minutes.

I was unsatisfied with the current joystick extenders as they spoil the joysticks and come off after a while so I have uploaded a seperate joystick with twice the length to be installed the same way, let me know if you need other lengths.

Please post makes if you enjoy the design :)

Update V2: added a bit more clearance to the bottom of the print for layer changes and sagging. It should print on all slicers properly now. Extended joystick extended from 8mm to 12mm ( original is 4mm)

Update V3: Increase tolerance for lower end printers, it should print properly on all machines now. Small ring along the edge for better grip added.

Added two experimental designs which doesnt work well enough, maybe someone can figure out how to make it more grippy.

EDIT: 16/07/17: Added source files from solidworks for easy customization. Feel free to customise the grips to your liking and post remixes if you do. The other configurations are avaliable in the configuration tab.

Print Settings

Resolution:

0.2mm or lower

Infill:

5%

Notes:

Rotate 90 degrees in the x axis so it is upright and print with supports. I do not recommend going above 0.2mm layer height as supports will stick to the surface and be extremely hard to remove. Layers also break easily above 0.2mm.

You might need a raft if your printer or slicer is not calibrated properly. Feel free to mess with the print settings. Even at low infill settings it should be strong enough with 3 shells.