3D Printing an Xbox Battery Cover: Step-by-Step Guide & Free STL Files

Ever lost a battery cover for your Xbox controller? Yeah, me too. It’s one of those small but essential parts that seems to disappear right when you need it. But instead of overpaying for a replacement online or having to do the world-famous Xbox Controller No Battery Pack Fix, I decided to 3D print my own—and you can too.

A printer is now more accessible than ever, and options are available for almost any budget. Even if you don’t own a 3D printer, your local library might have one you can use for free.

In this guide, I’ll walk you through how to 3D print a replacement battery cover for your Xbox 360 or Xbox One controller and share some handy resources to make it happen.

Why 3D Print a Battery Cover?

Let’s be real—Xbox battery covers are way too easy to lose. And when you go looking for a replacement, you either find overpriced options or cheap knockoffs that don’t fit quite right.

If you’re really in a pinch, I’ll never steer someone away from the world-famous penny fix for Xbox controllers. But we all know pennies and aluminum foil aren’t a real long-term solution.

Instead of taking risks, 3D printing lets you make a custom cover that fits your controller perfectly, and you can even tweak the design or color if you want something unique.

Plus, if you print your own, you’re not waiting around for shipping. You get exactly what you need, exactly when you need it.

Don’t Have a 3D Printer? Check Your Local Library

Not everyone has a 3D printer at home, but the good news is, you might not need one. Many public libraries now offer 3D printing services, and in most cases, they’re free if you have a library card.

For example, the Elmhurst Public Library in Elmhurst, Illionis lets members submit 3D print jobs, making it easy to print small parts like a battery cover. Your local library might have a similar setup—just check their website or ask a librarian. I know our local library system (top 50 metro) has a 3D printing lab at the main library and various branches with smaller areas and a selection of devices.

Every library has its own process, but typically, you just need to submit your file online or bring it in on a USB drive. Some libraries will even let you watch the print in action or do the printing yourself.

Where to Find 3D Print Files for Xbox Battery Covers

No need to design a cover from scratch—other gamers have already done the hard work for you. Here are a couple of solid options:

• Xbox 360 Battery Cover: A well-designed replacement that should fit most controllers. You can grab the STL file from this Reddit thread.
• Xbox One Extended Battery Pack: If you want to go beyond just a cover and build a custom rechargeable pack, check out this detailed Instructables guide.

Once you’ve downloaded the file, you’re ready to print.

3D printing items is nowhere near as challenging as it used to be and there are many , detailed resources available to help get you started. Below I’ve outlined the steps needed to 3D print your controller battery compartment or cover.

3D Printing Your Battery Cover

So to get started, you will just need to drag-n-drop the How-to Schema block in the Gutenberg editor. The How-to Schema block can be used on pages that contain a How-to in their title and describe steps to achieve certain requirements.

Total Time Needed :

2

Hours

30

Minutes

Total Cost:

$0

USD

Required Tools:

– 3D Printer

Things Needed?

– Filament

– STL File for Battery Compartment/Cover

Step-By-Step Guide:

Step 1 – Check the file:

Open the STL file in a slicer program like Cura or PrusaSlicer to make sure everything looks good. Look for any missing details, misaligned edges, or scaling issues.

Step 2 – Modify if necessary:

If the fit isn’t perfect, you might need to tweak the design slightly in a program like Tinkercad or Fusion 360. Most slicers also allow small adjustments before printing.

Step 3 – Pick the right material:

PLA is the easiest to print and should work fine for a battery cover, but if you want something tougher, PETG or ABS is a better choice. ABS is more heat-resistant but requires better ventilation due to fumes.

Step 4 – Adjust your print setting:

For a strong, durable print, aim for a layer height of 0.2mm and an infill of at least 30%. Supports shouldn’t be necessary unless your model has overhangs.

Step 5 – Submit or start the print:

If you’re using a library’s printer, follow their submission guidelines. If you have your own, slice the model, load up your filament, and start printing.

Step 6 – Test the fit:

Once printed, snap it onto your controller. If it’s a little too tight or loose, you can adjust the scale in your slicer and print another one. Light sanding can also help smooth rough edges.

Frequently Asked Questions (FAQ):

Final Thoughts

3D printing a replacement battery cover is one of those simple but super useful projects. Whether you’re fixing an old controller or experimenting with custom designs, having access to 3D printing opens up a ton of possibilities.

If you end up printing one, let me know how it turned out! Did it fit perfectly, or did you have to tweak the design? Share your experience or custom design in the comments below —I’d love to hear about it!