Student Case Study: Solving the Xbox One Controller Battery Cover Issue
- jonathang22
- May 14
- 3 min read
Updated: May 28
By Jace: Selkirk College Student of the Digital Fabrication a Design program.
Challenge:
When I switched to rechargeable battery packs for my Xbox One controller, I noticed they were
slightly larger than regular AA batteries. This made the battery cover either get stuck or put a lot
of strain on it. Changing the batteries became a hassle, and I started worrying that I might end
up damaging the covers. I was especially concerned that constantly forcing the cover on and off
could eventually cause the plastic to crack or warp, shortening the lifespan of the battery covers
Solution Options:
1. Buy Rechargeable AAs instead:
○ Pros: Purchasing a set of rechargeable AA batteries would resolve the issue of
the battery cover fitting properly. There would be no need for modifications or
other changes.
○ Cons: The primary downside was that this solution would render my current
rechargeable battery packs obsolete. Buying new battery packs would also be an
additional cost
2. Make Custom Battery Covers:
○ Pros: This would involve designing a custom cover that would provide the
necessary space for the slightly larger rechargeable battery pack. The benefit of
this option was that I could solve the issue without replacing the battery packs
themselves. A custom design would ensure the cover fits snugly without stress.
○ Cons: The difficulty with this solution is the complexity of reverse-engineering the
cover. It would require accurate measurements, which could be time-consuming
and technically challenging
3. Use No Battery Covers:
○ Pros: Removing the battery cover entirely would allow for an easy solution, as
there would be no constraints on the battery size. It’s a free and quick fix with no
need for further modifications.
○ Cons: The main downside was the exposed batteries. Without a cover, the
batteries could easily become dislodged. Additionally, I would risk losing the
battery covers over time
4. Force Battery Covers on:
○ Pros: This would allow the existing battery cover to remain in use, ensuring that
the protection for the batteries remains. The cover would stay intact, and the
batteries would remain secured.
○ Cons: Forcing the cover onto the controller could cause damage, It would also
make swapping the battery packs more difficult and cumbersome.
Solution Chosen:
I decided to proceed with the solution of making custom battery covers. This solution was ideal
because it addressed the issue directly without requiring the purchase of new battery packs.
Additionally, reverse engineering is fun and the availability of a 3D scanner and Tempus’s printer
provided through the DFAB program made this solution practical.
Result:
The process of creating the custom battery covers began with scanning the original controller
case. I used the 3D scanner to get a very close model of the existing battery cover. After
gathering the scan data, I took measurements from the battery cover to refine the model.
Next, I modified the 3D model to accommodate the slightly larger rechargeable battery pack.
This required adjusting the depth of the compartment where the battery pack would sit,
providing the necessary extra space. The only issue encountered was incorrectly estimating the
corner radius, which I fixed in my next test.
In the future, If I didn't have access to a 3D scanner or the necessary tools for creating a custom
cover, I would likely opt for rechargeable AA batteries instead, as they would fit into the existing
cover and avoid work with other devices. However, reverse engineering is fun.
Overall, the solution was a success. The custom covers provided the additional space needed
for the rechargeable battery pack. The stress on the cover was eliminated, and I didn’t
experience any issues with forced fit or damage to the covers.
