RK 2020 PS5 Controller Back Shell Mod

After playing my RK2020 emulation handheld for around 20 minutes, my hands start to cramp up. While it is an impressively powerful unit, it has terrible ergonomics especially for large hands. I got the idea to replace the rear shell of the unit with a 3D printed shell with grips from a console and this design was born. The design is based on the PS5 “DualSense” controller set to release with the PS5 in late 2020. The PS5 controller is a perfect fit for the RK2020. This custom back shell is an accurate recreation of the actual controller that will be shipped with the PS5 around December of 2020.

This mod is easy to perform!

This design replaces the stock back shell. Installing the printed part requires a small Phillips screwdriver with an 8mm or less diameter shaft that is at least 31mm long
Requires removal of the battery. Take care when unplugging the connector. No soldering is required.

Features of the design:

• This high accuracy model is a replica of the actual shape of the PS5 DualSense controller while maintaining full access to all ports and buttons.
• The location of the D-Pad and ABXY buttons are consistent with the location on the actual PS5 controller which has excellent ergonomics.
• The battery compartment has been extended 20mm in length and 11mm in depth (no increase in width) to 98.5mm x 46mm x 17.5mm.
• Airflow has been vastly improved for extended gaming sessions to maintain maximum frame rates, and to protect the battery and U/GPU/RAM from overheating.
• Audio port has been ported to the inside of the right grip, away from your hand and has a slightly flared design to help improve mid and lower frequency response of the speaker.
• The L1 and R1 button wells have been adjusted by 0.75mm to help improve button feel.

There are dozens of hours in the design and testing, I have printed multiple prototypes to get the features just right. There should be no issues provided your printer prints accurately. If you have any questions or comments, leave them in the comments and I’d be happy to help you out! Enjoy the hours of gaming!

Layer Height: Tested at 0.15mm and 0.2mm with no issues. 0.15mm provides a better surface finish.
Perimeters: Tested at 2 perimeters
s: None
Infill: Tested as low as 10% gyroid infill
Nozzle diameter: 0.4mm or less (only 0.4mm nozzle has been tested)
Finished print is approx. 80g in weight at 10% infill using PLA material.
The model is designed to be printed with the flat face with slots facing down.
The overhangs in this model are 55 degrees or less with the exception of the audio port, but it is a small and not visible so bridging is acceptable.
Ideal for SLA, but I designed it primarily to be printed by FDM/FFF machines since that is what I use.
There are small features in this model. Precise extrusion is important for best results.
I have printed these parts on a stock Prusa MK3S with Generic PLA settings (210C nozzle, 60C bed) with great results and no post processing. The .stl contains 88,000 triangles.