DJI FPV Remote Controller, "Controller Pad"

thingiverse

I "fly" an FPV drone simulator just as I fly a drone in the real world--with the DJI controller suspended from my neck with a controller neck lanyard. The DJI controller is wired into my PC while flying the simulator, but due to the location of the cable port on the DJI controller, the USB cable jabs into my chest. This protrusion of the cable prevents the DJI controller from lying flat on my torso and this became more than a minor irritation--after several weeks of use, the connection between the USB-C port and the circuit board inside the controller was starting to fail due to the strain that was being imparted to the cable by the controller pressing against my chest. The controller began randomly losing connection with the PC if I stressed the USB cable too much. A solution to these problems is this "Controller Pad" part, which serves as a "standoff" against your chest, allowing for cable clearance and cable strain relief. The area on the DJI controller where this part mounts is a pretty complex curved compound contour, but I was able to achieve a nice matching surface on this part by scanning that area on the controller with a 3D laser scanner (a perk of my workplace). The thickness of the part allows for neatly mounting the part to the controller with two strips of 3M VHB 5952 (the 1/2" width stuff). That adhesive tape is kind of spendy--other adhesive tapes may work for you, but I can say that VHB 5952 definitely works great. The part shown in the photos was SLS 3D printed with unfilled PA12 nylon (another perk of the workplace) but I'm sorry to say I have no wisdom to share on what printer settings to use as I have essentially zero experience with that stuff. The two different types of right-angle USB-C adapters shown in the photographs are available on Amazon by searching for: "Poyiccot (2-Pack 90 Degree USB C Type C Male to Female Adapter, Right & Left Angled 90 Degree USB-C USB 3.1 Type-C Male to Female Extension Adapter for Laptop & Tablet & Mobile Phone" "USB C Angle Adapter [2 Pack] 90 Degree USB-C Type C Male to Female Adapter, Upward & Downward Angled USB-C USB 3.1 Type-C Extension for Laptop & Tablet (USB-C Up/Down, Black)"