Ladies and Gentlemen ! I present to you all the Xbox360 Controller Teardown video (presented below). The teardown involves taking apart a ‘Rock Candy’ Xbox360 controller and was conducted using a single *00 screwdriver from Home Depot. The Xbox360 Controller is encased in a two-part ABS plastic casing, formed via injection molding, which is held together via the means of seven Phillips screws. Additionally, all buttons (including their plastic covering), triggers, trigger mechanisms, D-pad and joysticks found on the controller are manufactured using injection molding.
The D-Pad is composed of a two part clip-in button, which is secured in between the casing and the logic board and informs the system via four strain gauges found on the logic board. Additionally, as demonstrated in the image below, the logic board contains four LED lights for the ‘Home’ button display and uses strain gauges to detect when the button that is pressed.
Each Joysticks work via an analog stick system composed of a plastic joystick mounted on a double potentiometer system, which stacks them at right angles to each other. Depending on where the joystick points, each potentiometer will register a certain resistance, informing the logic board where the joystick is pointing and thus enabling user control. Additionally, this system includes a button mounted on the logic board, to allow the controller to register when the user presses the joystick in.
The bumper buttons (RB and LB) are composed of a single, plastic piece that curves around the logic board and is held between the casing and two buttons. These buttons are mounted on the logic board and notify the controller when the bumpers are pressed.
The triggers and trigger mechanisms are attached to the controller via a snap-fit mechanism and function in such a way that when the trigger is pressed is spins a receiver mounted on the logic board. This rotation sends a current to the logic board, which enables the user to accurately trigger the joystick and inform the system of how much they want this function to be active.
The controller rumble is caused by two DC motors attached to unbalanced weight, which in hand are attached to the logic board via cables.
Finally, the logic board is connected to the console via a controller cable, which is attached to the logic board via a series of cables, which I believe are welded onto the controller.