Replacement "Transformable" D-pad for Xbox 360 controller

thingiverse

A replacement for the Xbox 360 controller's "transformable" d-pad is possible to create using FDM technology. This type of controller features a spring pushing on the dpad while a screw pulls down on the shaft, eventually leading to fatigue. However, it's relatively easy to disassemble and reassemble with a new d-pad, getting the controller working again. For this piece, strength is critical, but it can be achieved by annealing the part after printing. I found that heating the headbed up to 75C for an hour after printing was sufficient to achieve the desired result. For FDM printing, I recommend using the "nocurve" model of the STL file, which has proven to work well. I initially created a version with a soft curve on the surface, similar to the original dpad, but it didn't produce good results in FDM due to poor surface finish. To overcome this issue, I removed the curve and developed the "dpad-nocurve" model, which is recommended for printing. For those with high-end printers, I've also uploaded the "dpad-curve.stl" file, featuring a shape closer to the original part.