OG Xbox Prototype Build

Recreating the Original Aluminum Xbox Prototype

The original aluminum Xbox prototype has always fascinated me. When it first appeared in magazines and on gaming websites, it looked futuristic and powerful, unlike anything else at the time. As a kid, I had no idea that the final retail design would look completely different. That early prototype left a lasting impression, and I knew one day I wanted to recreate it.

After spending a month upgrading and fine-tuning my 3D printers, this project became my first major test of their new capabilities. I located a high-quality STL model of the prototype online RIGHT HERE and started printing right away. Since my printers were freshly upgraded, I had to go through several rounds of calibration. I dealt with issues such as under-extrusion, adhesion problems, and inconsistent layer bonding before finding the optimal settings.

Once dialed in, I began printing both halves of the case simultaneously using white PETG filament. PETG was chosen for its balance of strength, temperature resistance, and surface finish, which made it a good substitute for the metallic look I plan to achieve later through sanding, priming, and painting.

During the print, I encountered a rare and unexpected issue. The glass print bed on one of my machines bonded directly to the part, causing a section of glass to embed itself into the PETG surface. I carefully removed the glass fragments, and the small damaged area will be repaired later with Bondo before final finishing.

Unfortunately, right after ordering materials for the next phase, I suffered a setback unrelated to printing. A broken skateboard truck caused a hard fall that resulted in a third-degree AC sprain in my right shoulder. Because of this, the project is temporarily on hold until I regain full mobility.

Once I recover, I will resume work on the case, including sanding, surface repair, priming, and painting. This will not just be a display piece; the finished build will be a fully functional original Xbox, as I plan to transplant authentic OG Xbox hardware into the 3D-printed prototype shell. My goal is to replicate the clean, industrial look of the original aluminum Xbox prototype while maintaining the precision and durability that modern 3D printing makes possible. Updates will follow once progress resumes.