I've been wanting to print something in 3D from one of those online services for a while now, so I decided to start with a battop handle for a ultrastik 360. This is a work in progress, so I may end up working through a few issues.
Design:

The design I'm going for is to have the handle 3D printed in 3 different parts, with one of the parts being an optional "plug" to fill up the interior of the handle if it feels too light. Basically, you insert a hex nut into the base of the handle that will screw onto the joystick. The cap has a recess for the button hardware. Once the wires are attached to the button and the LED, you attach the cap onto the base. I still need to bore a hole down the center of the joystick shaft to run the wires, and I'll need a slip ring at the base to keep the wires from twisting up.
Most of my design is based around these posts:
http://forum.arcadecontrols.com/index.php?topic=132356.0http://forum.arcadecontrols.com/index.php/topic,108490.0.htmlParts:
- M10-15.0 10mm Hex Nut
- Standard RGB LED
- Philmore Mini Push Button Switch #30-146 (The 3D model is designed specifically for this model of pushbutton)

Materials:
I wanted to print the handle in a type of plastic (either white or transparent) where an RGB LED would make it glow. The service I am looking at (
www.shapeways.com) has a few different materials that fit this bill, but they vary in price. My 3D model in standard “strong and flexible” white plastic was around $20. The same model in white or transparent “detail” plastic was $58, and in “frosted detail” was $49. Since this is my first 3D print, I figured I’d go with the “strong and flexible” white. My only problem now is waiting to see how well the LED lights it up.
Here's a link to the item on Shapeways if you want to print it yourself:
http://shpws.me/Dq4J