Revolutionizing Gaming Controllers with In‑House SLS 3D Printing

Battle Beaver Customs is redefining the competitive edge for gamers by producing high‑performance, custom controllers that respond faster and feel more precise.

Beat Competitors to Market

Modern console generations undergo frequent internal redesigns. When Sony updated the PlayStation 5 controller’s interior, Battle Beaver’s team had to adapt their mounts and button housings within 48 hours. With the SLS‑powered Fuse 1, they moved from weeks or months of design‑to‑production to a matter of days, keeping them ahead of rivals.

From Outsourced Injection Molding to In‑House SLS Production

Initially, Battle Beaver sourced internal parts from China. Each Fuse 1 build chamber can print 500–800 pieces in a single run, allowing on‑demand batch production that eliminates long lead times and supply‑chain uncertainty. The transition to SLS also lowered costs and gave the team the flexibility to experiment with new geometries.

While the Form 2 SLA printers remain valuable for smooth‑surfaced, external components such as the SmartPad d‑pad replacement, nylon SLS offers superior bonding with epoxies, glues, and even soldering tools thanks to its higher thermal capacity.

Producing Legacy Parts on Demand

As the catalog of supported controllers expands, the ability to print small batches of obsolete parts keeps the company competitive. A customer can request a vintage controller modification, and the team simply loads the corresponding STL file into the Fuse 1, prints the parts, and delivers a fully upgraded controller—no costly tooling required.

Request a Free Sample Part

Experience Formlabs SLS quality firsthand. We’ll ship a free sample part directly to your office.

Unexpected Advantages of In‑House SLS

Batch sizes of 500+ parts make media blasting time‑consuming. To streamline this, Battle Beaver installed a custom rack that rotates parts inside the blasting chamber, cutting post‑processing time dramatically. After nearly a year of use, the Fuse 1 has become an indispensable tool in the team’s workflow.

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