Preceding one of the most anticipated product launches in consumer electronics history, Stratos optimized ergonomics and control placement for ease-of-play in the Xbox controller.

Meet and exceed the performance specifications of every controller on the market, while maintaining the lowest possible cost of goods.

A team of Stratos engineers and designers were initially asked to develop the electrical and firmware designs for the controller and plug-in memory modules. Stratos’ involvement gradually grew and led to design contributions in several areas of the mechanical design including the triggers, analog buttons and motor capture as well as the final mechanical design of the memory unit and its interface to the controller.

Stratos and Microsoft began work on the Xbox project after collaborating on several past projects that included research and development of force-feedback conditions for the Microsoft Sidewinder game controllers. With Xbox, this relationship extended into comprehensive development support including electrical, mechanical and firmware development and industrial design collaboration.

Mechanical Engineering

Created the first working POC (proof-of-concept) prototypes for the controller and detailed designs for the analog buttons, triggers and docking mechanism for the memory units. Generated several hundred evaluation units for early development testing, meeting requirements for rapid detailing of the entire mechanical system for quick-turn injection molding. Managed the entire design and assembly of these units.

Explored new mechanical architectures to optimize design for a Japan-specific controller. Through exacting CAD models and close collaboration with Microsoft’s internal ID team, roughly 15% volume was removed from the controllers without sacrificing any of the original functionality.

Electrical Engineering

Evaluated dozens of possible chip combinations and user interface technologies to meet the exacting price/performance requirements for the controller. Worked closely with the mechanical team to tune the controller?s electrical performance to perfection. Optimized the electrical layout several times to trim the overall PCB size.

Met the FCC’s and CE’s rigorous EMC standards through innovative design modifications as the product progressed to production. Coordinated several builds ranging from 6,000 to 20,000 units with local prototype shops as well as Microsoft’s overseas contract manufacturing partner.

Industrial Design

Reduced the size of the domestic Xbox controller for the Asian market. Collaborated with the client and in-house team of mechanical and electrical engineers to make intelligent design decisions and trade-offs, which saved significant development time and testing.

Drafted concept sketches, surface and detail development and SLA models. Provided continuity in design to the domestic controller and helped optimize ergonomics and control placement for ease-of-play.

Software Engineering

Designed firmware that allowed the Xbox controller to communicate with the Xbox at a rate four times faster than standard game controllers, thus creating a more realistic gaming experience.

Stratos-designed firmware controlled the Xbox Interface Device (XID) protocol along with the task of acquiring and calibrating the numerous controls on the device. Iterated firmware and prototype devices several times to produce the desired end product.

Added dynamic control calibration to increase the effective resolution of the controller’s joysticks and triggers, allowing for a high-resolution, low-latency game controller.

Project Management

Organized and led the creative project team of mechanical, electrical, and software engineers at Stratos through flexibility and close collaboration with Microsoft. Established daily/weekly communication with the Microsoft team, built internal issues lists that were reviewed on a weekly basis, and kept internal teams on time and on budget.