Intro: PS4 Controller Breakout Board PCB

In this Instructable, I'll describe the process I used to create a breakout board for my broken PS4 controllers. When I took mine apart, I discovered that most of the buttons connect via a membrane keypad, and a custom PCB would be required in order to make the necessary matching contacts.

STEP 1: Custom Board Outline

I traced the board outline from some scans of stripped-down PS4 controller boards I found online using Adobe Illustrator. I exported this outline, also containing the nonplated through holes, as a DXF. I used Fusion 360 to design this PCB, and was able to import the DXF into the 3D space, then push it to a board outline in the electronics space. The NPTHs were automatically recognized as such. I 3D printed this shape to test its fit in the controller, and the registration pins lined up beautifully.

STEP 2: Device Footprints and Routing

I created a new device for the membrane contacts, spacing the pads using measurements from the original board scan. I also modified the footprint of an existing joystick to match the dimensions of the one used on the PS4 controller. Here are the Fusion 360 tutorials I followed:

STEP 3: Order Boards and Assemble Prototype

I got my initial prototype boards printed at OSH Park. I soldered on the joysticks and header pins, and connected up some prototyping wires to extend out the back of the controller, where I had cut a hole.

STEP 4: Connect to Solderless Breadboard

I reverse-engineered the connections by hooking everything up to a solderless breadboard, and probing each wire with an LED while pressing the buttons on the controller. Eventually, I could work out which pins connect to what switch.

STEP 5: Revise and Enjoy!

So I revised the design, consolidating ground pins, and adding in the speaker contacts and three mechanical switches that live under the trackpad and share/options buttons on the PS4 controller. I had the boards fabbed this time by JLCPCB. You can pick one up in my shop, and also download all the open source files on Github.

Bill of materials:

Thanks for reading my Instructable, and I look forward to hearing your PS4 controller upcycling project ideas in the comments!