Our Guitar Controller (And How We Made It)
The guitar controller is one of our most ambitious internal builds to date.
It is a fully custom Smash Bros controller designed and fabricated entirely in house, from the CAD model to the final solder joint. Every part of the controller, its structure, electronics, and internal layout, was intentionally designed rather than adapted from existing hardware.
This project reflects the way we approach engineering at Rease’s Workshop: unconventional in form, but uncompromising in execution.
A Fully 3D Printed Body
The entire body of the controller was designed in CAD by Ian Rease and produced through 3D printing by our amazingly talented friend James Dunzweiler, giving us full control over geometry, proportions, and internal structure. This freedom was critical when integrating our custom electronics into a guitar shaped body that was never designed to house them.
The external profile is based on a mustard base style guitar, but the internal architecture was purpose built. Mounting points, wall thicknesses, and internal clearances were all engineered to support the electronics securely while maintaining structural rigidity. The result is a shell that functions as both enclosure and framework, rather than just cosmetic housing.
Hand Wired Electronics
All electronics inside the controller are fully hand wired.
Each button is individually soldered and routed directly to a Raspberry Pi Pico. We also used a custom made PCB for the USBC port. This approach allowed complete control over input behavior, routing paths, and internal organization.
Hand wiring also enabled a clean, intentional internal layout. Every wire serves a purpose, every connection is accessible, and the controller can be opened, serviced, or modified without disturbing the overall structure.
Powered by a Raspberry Pi Pico
At the core of the controller is a Raspberry Pi Pico, which handles all input processing.
The Pico was selected for its compact size, flexibility, and suitability for custom controller logic. Its footprint integrates cleanly into the internal layout, and its capabilities allow the controller to function as a fully custom input platform rather than a fixed design. This choice supports both experimentation and future iteration without requiring structural redesigns.
Why This Project Matters
The guitar controller exists as an exploration of form, fabrication, and control design.
Projects like this allow us to push our engineering skills beyond conventional constraints, refine our fabrication techniques, and explore ideas that inform future work. It stands as a demonstration of what we value as a studio: thoughtful design, technical depth, and a willingness to build something ambitious simply because it's worth building.