Playstation Controller Clone #designbycapture

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Judges/Everyone please watch my submission video below, which shows how I generated the model with photogrammetry using Autodesk ReMake, and printed it using an Ultimaker 2+ (https://vimeo.com/190187492)

Workflow

I decided to use the turntable approach for taking the photos. For easy and accurate rotation, I designed a turntable with worm drive, and rigged the controller on the turntable with modeline clay and paper clips. I have uploaded my turntable for everyone to try here: https://www.myminifactory.com/object/25004

The Playstation controller has smooth, shiny, black surfaces which are not ideal for photogrammetry. To deal with this, I applied cornstarch over the surface, which adds color variation and a matt finish that allows Autodesk ReMake to generate a clean model.

After the model generated successfully, I used Autodesk ReMake's editing tools to delete the wire supports and smooth out the surface.

Lighting and Camera

I used three halogen work lights (2 x 500W, 1 x 250W) with translucent velum paper from the crafts store as diffusers. The background sheet is a piece of white vinyl from the fabric store. My camera is an old Sony NEX-5N, set to manual to keep the shutter speed and aperture constant. The ISO is 100. The camera is mounted to a Gorillapod. I used a remote trigger ($2 from AliExpress) to ensure crisp photos.

The Print

I printed the model with an Ultimaker 2+ in white PLA at 0.05mm layer height on a 0.4mm nozzle for high detail. Print time was about 30 hours at 10% infill. Seams between the parts were patched and smoothed with a little modeling putty. The result is a highly detailed, dimensionally perfect replica.

Uploaded Files

I have uploaded:

- "PS Controller Decimated" in OBJ and STL as the rules require. These are the complete undivided model of the controller, which others can use for customizing.

- Four "PS-Ctrlr-..." STL files which is the model divided into four parts for easy printing. Only the thumbsticks require supports.

Customization

The model is a bluetooth wireless Sony Playstation controller. I plan to customize the exterior of the controller with a steam-punk themed shell that will (1) look amazing, and (2) add bulk for better hand ergonomics (similar to an XBox controller)

Thanks for Viewing!