Sustainability Report: Xbox One Controller
ECS 511: Sustainable Manufacturing
In Syracuse University’s ECS 511, I wrote a three-part sustainability report on the Xbox One Remote, evaluating its environmental impact and proposing design modifications to minimize it.
First Part: Enhancing Repairability
A commonly overlooked strategy for reducing a product’s carbon footprint is designing it with repairability in mind. When users can fix their remote instead of replacing it, the environmental impact shifts from manufacturing an entirely new device to producing only the necessary replacement parts.
If a controller is difficult to disassemble, fewer people will have the tools, knowledge, or motivation to attempt repairs. To assess the Xbox One Remote’s repairability, I performed a full teardown, identifying key design obstacles. One such obstacle was the use of T8 security fasteners, which require a specialized tool. Since I didn’t own this tool, I had to go out and purchase one—an inconvenience that might discourage a number of users from attempting repairs.
Additionally, I compiled a Part/Asy bill of materials (BOM) for further analysis in later sections of the report.
Recommendation(s): Replace T8 security fasteners with standard screws, as their unneccesary security benefits make repairs more difficult.
Image 1: Xbox Disassembly View
Second Part: Material Assessment
In the second part, I analyzed the controller’s material composition, the supply chain journey of its materials, potential health hazards, and alternative materials that could reduce its environmental impact.
The controller primarily consists of ABS, acrylic, epoxy, natural rubber, copper, nickel, steel, and neodymium magnets. These materials undergo extensive processing, from extraction to manufacturing, contributing to the device’s carbon footprint. ABS plastic, which makes up the majority of the enclosure and buttons, is durable but not environmentally friendly due to it being derived from petroleum-based sources. Similarly, PTFE-coated neodymium magnets, used in the controller’s motors, pose environmental and health concerns due to hazardous chemical coatings.
To improve sustainability, I explored material alternatives. Switching from PTFE coatings to natural rubber could reduce toxicity, while increasing the percentage of recycled ABS plastic would lower emissions. Additionally, using a bio-based polymer for select components could further decrease environmental impact without sacrificing performance.
Recommendation(s): Increase the use of recycled ABS in the controller’s plastic components and replace PTFE-coated magnets with natural rubber-coated alternatives to enhance sustainability while maintaining durability.
Image 2: CF vs % Recycled Content
Image 3: Material Use Safety Rating
Image 4: Material Journey Map
Third Part: Life Cycle Assessment and Material Alternatives
In the third part, I conducted a Life Cycle Assessment (LCA) for the Xbox controller’s outer enclosure, comparing the current material (ABS) with two alternatives: Nylon-11 and PLA. The LCA evaluated carbon emissions across key stages, including material synthesis, transportation, part production, and disposal.
The results highlighted two critical factors affecting sustainability: the location of material synthesis and the durability of each material. While ABS is widely used, its petroleum-based nature contributes to high emissions. PLA, despite being bio-based, lacked the necessary durability, leading to a higher replacement rate and, ultimately, a larger carbon footprint. Nylon-11, on the other hand, offered a significantly lower environmental impact due to its durability, requiring fewer replacements over the product’s lifetime.
Recommendation(s): If reducing carbon emissions is a priority, Nylon-11 should be adopted as a more sustainable alternative to ABS. However, if cost considerations are a determining factor, the trade-offs between sustainability and expense must be carefully assessed to find the optimal balance.
Image 5: LCA Results Chart