Designing PS5 Paddles for INCNTRL.CO.UK
3D Printed Controller Paddles
OVER 2000 PARTS MASS PRODUCED
“well made with the paddles being the best paddles I’ve ever felt on a controller”
Overview
Our work with INCNTRL on their PS5 controller paddles began with a clear objective. They needed a paddle system that felt comfortable under the fingers, delivered reliable actuation and could withstand heavy daily use. Off-the-shelf parts were not meeting their standards, so the entire design was developed from scratch.
The project followed an iterative cycle of prototyping, testing and refinement. Each version was 3D printed and fitted to a real DualSense controller, allowing us to make targeted improvements to ergonomics, actuation feel, curvature and durability. Through this process we shaped a design that met INCNTRL’s specific functional and comfort requirements.
Product Details
Client: INCNTRL.CO.UK
Design: AXIS VDF (co-design and CAD development)
Controller Platform: Sony PS5 DualSense
Process: Iterative 3D printed prototyping
Material: PETG & production-grade FDM formulations
Finishing: Light sanding, Heat treated
Production: Over 2000 units manufactured
Goal: A paddle system ready for scale
“AXIS VDF completely transformed our product and processes.
Using his knowledge, not only did Matt help us further develop our product to make it more ergonomic, cost effective to produce and look better than ever, he also supported us by creating templates, holds and more for our building process.
Saved us time + money alongside making us more money at the same time!”
Case Study Highlights
After finalising the design through extensive prototyping, we transitioned the project into mass production. The manufacturing workflow was carefully optimised to ensure reliability across every batch, including improved part orientation, reinforced internal geometry and consistent post-processing.
This allowed us to produce more than two thousand paddles with uniform quality and dependable performance. The INCNTRL paddles have since been used by a wide range of customers, many of whom have highlighted the comfort, responsiveness and overall feel compared with other third-party options.
Our work with INCNTRL demonstrates how a concept can be refined through rapid prototyping and scaled into a dependable production product, balancing ergonomics, durability and manufacturability.
Gallery
