RE: EPIC BUILD!!!

Sean_Miller — Wed, 11 Dec 2019 00:51:50 GMT

Sorry to hear this has happened.

It is definitely possible to custom make such a solution. A 3D printer would be needed to pull it off. However, the biggest thing is time. For me, I'd estimate 70 to 100 hours of research, design, printing, and code for such a build. Typically making a second one takes under 8 hours, but that first one can be beast.

So, with a noble build like this that you'd want to get right with the first version, it probably would be best not to make it a surprise and extend your deadline. Rather, you'd want to partner with him to get his input on how he would like to control it. For example, if he likes shooters, would you want the "Left Trigger Aim" function actually trigger from him closing his left eye, or would you want a device that triggers "aim" by his arm, leg, or foot.

Here's a potential build approach:

Grab an Xbox controller and discuss how he'd like to emulate the control every single button. For example, would he want a big joystick for the arm and held joystick for the other hand? Make sure there is no conflicts in execution of actuating the buttons for required sequences used in the games he most likes. In other words, don't try to control two joysticks with the same foot. (2 hours)
Explore the controller signal options (wires or wireless). For example, you could have a station that plugs directly into the USB port of the XBox that wirelessly receives control signals from your custom devices. (10 hours)
Draw some concepts on paper each device that would be needed. There is no limit to the number of devices required to emulate the one controller. However, if you don't go wireless, it will be a mess. (2 hours)
Once you get his preferred controls, you'd then need to get his key measurements to design the controls. (1 hour)
Determine your microcontrollers. ESP8266 could be an option for the devices and the hub here using web sockets for communication of controller/button positions. If you wanted to use visual gestures as well, the BeagleBone AI or Raspberry Pi 4 may do the trick. There is an Arduino library (https://www.instructables.com/id/Create-a-Joystick-Using-the-Arduino-Joystick-Libra/) that could come into play. (10 hours)
To get the most out of games, you may find that you need to use hall effect sensors in your custom devices for analog signals if off-the-shelf joysticks won't work for him.
Breadboard your microcontrollers, code, and test until you get expected results from all devices. (10 hours)
Get Autodesk Fusion 360 to design your parts. 3D print them with a low density and test them for comfort. Print the final with a high density for longevity. (20 hours)
Done

Don't let this list discourage you. I can definitely see it coming together for you.

Let me know if you have any questions,

Sean