Barcade Quick & Crash
Arcade Controller Reverse Engineering

Legacy Degradation & “Design Intent” Restoration

The primary challenge was not only the overall state of available samples but more importantly the availability of undamaged ones. Barcade provided a several samples in varying conditions, with one standout example being almost new old stock. Supplied with a sample set we began reverse engineering and creating new clean CAD data. we had to distinguish between the as-worn reality of the parts and the original design intent, ensuring the new CAD models corrected for physical degradation.

Manufacturing Conversion

The original parts were designed using the injection-moldering process, something very common in todays world. However the way the parts were designed its clear they were never meant to last as long as some have. Converting these to resin casting required a complete rethink of the internal geometry. Unlike injection molding, which uses high pressure to force plastic into a steel tool, resin casting relies on gravity and vacuum pressure in silicone molds. We had to redesign internal ribbing and mounting points to ensure material flow while adding structural integrity to the areas we new were weak spots, without the benefit of high-pressure injection.

Precision 3D Scanning

We utilized high-fidelity structured light 3D scanning to capture the complex, organic curves of the original controller. This served as the foundation for our digital reconstruction.

Hybrid CAD Modeling

We performed scan-to-CAD modeling using the scan data for the exterior ergonomics but manually engineered the internal mechanical interfaces (trigger housing and sensor mounts) to ensure 100% compatibility with the original arcade electronics.

3D Printed Prototyping

Before committing to tooling, we produced 3D printed prototypes. This allowed Kemperle Industries and the Barcade team to perform “fitment and feel” tests with one of there pre deployed arcade cabinets. This ensued the ergonomics were perfect and the internal components fit snugly and aligned correctly for real world use.

Silicone Tooling & Material Selection

We opted for high-tear-strength and rigid silicone molds to capture every intricate detail. For the casting material, we selected a high-impact urethane resin. This resin offers superior impact, and abrasion resistance, as well as rigidity when compared to the original thin walled ABS plastic controllers. We specifically chose this material to withstand the “slamming” motion common in Quick & Crash gameplay when the controller is returned to the holster on the cabinet. As well as those clumsy moments when the controller tumbles to the ground.

Vacuum Casting
To eliminate air bubbles and ensure void-free parts, the resin was cast under a vacuum. This process ensures that the densest part of the handle—the grip—is structurally sound and feels “solid” to the player.

The collaboration between Kemperle Industries and Barcade successfully transitioned the Quick & Crash controller from an extinct legacy component to a high-performance, modern replacement. By bridging the gap between 1990s injection-molding constraints and modern resin-casting durability, the project achieved the following outcomes:

Structural Superiority & Material Performance

The re-engineered handles surpassed the mechanical properties of the original OEM parts. While the original ABS plastic was prone to fatigue and brittle fracturing, the new high-impact urethane resin provided:

• Enhanced Impact Resistance: Specifically engineered to survive the “slamming” motion into the cabinet holster and accidental drops to the floor.
• Optimized Internal Geometry: By redesigning the internal ribbing and mounting points for gravity-fed resin flow, Kemperle Industries eliminated the weak points found in the original thin-walled design.
• Solid Hand-Feel: The vacuum casting process ensured a void-free, dense structure, giving the grip a premium, “solid” feel that enhances player immersion.

Design Intent Restoration

Through a “Scan-to-CAD” workflow, the team successfully filtered out decades of wear and tear to recover the original 1999 design intent.

• Aesthetic Accuracy: The structured light 3D scanning captured the complex organic curves of the original, ensuring the replacement parts are indistinguishable from the originals to the casual eye.
• Mechanical Precision: Manual engineering of the trigger housing and sensor mounts resulted in 100% electronic compatibility, allowing Barcade to swap the new handles onto existing cabinets without any modification to the original arcade hardware.

Verification & Fitment

The use of 3D printed prototypes served as a critical “proof of concept” phase, yielding:

• Perfect Ergonomics: Physical testing on pre-deployed cabinets confirmed that the “quick-draw” tactile experience remained intact.
• Seamless Integration: Fitment tests verified that all internal sensors and triggers aligned perfectly, reducing downtime for Barcade technicians during the replacement process.

Conclusion

The project resulted in a sustainable supply chain for Barcade. By utilizing silicone tooling and vacuum casting, Kemperle Industries delivered a part that is not only more durable than the original but also cost-effective for low-to-medium volume production. The Quick & Crash cabinets remain fully operational, preserved for a new generation of players with hardware that is more robust than it was on launch day in 1999.

Key Achievement: Successfully converted an obsolete injection-molded part into a high-durability resin-cast component without sacrificing the “cult classic” tactile feel of the original game.