The midterm project for the Design For Manufacturing graduate course at CU Boulder was to find a consumer product assembly, create a full drawing and model package, and identify 3+ design aspects or flaws that could be improved upon. We selected the Xbox One controller, identifying issues with the bumper assembly and housing fitting that resulted in the need for extra spacers to transmit button push force directly into the “skeleton” of the assembly.

Our final report on the product included probable justification for geometries, vendors, and material selection. The analysis consisted of 44 pages of part, subassembly, and assembly drawings; 15 pages of DFA (Design for Assembly) analysis; 8 pages material justification; and 20 pages other miscellaneous analyses such as costing, tolerance stack, and design improvements.

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