Having owned our Vive for only 3 weeks, one of the controller started showing a known track-pad fault. We contacted HTC and for those who have done this know what a waste of time it is. To cut a long story short and 3 weeks without a controller, we eventually received a refurbished well used not our new controller back.
I decided to try to protect the controllers and avoid future dealings with HTC customer services. This was my solution.They only add 2ozs to each controller so its nothing compared to the damage they will save,the protectors have been tested for two weeks with various games and have not shown any issues as all the sensors are still on show to the lighthouses.
My Wife CJ made the safety straps from para-cord after reading how many have snapped during game play I would advise you change yours soon, there's plenty of Instructions online to make your own or buy better ones than HTC provide.
These are for personal use only don't sell them as they took me weeks to design and after many prints I'm offering them for free to the 3D Printing community, I only ask that If you make them please add them as a make I'd love to see them.
Here's a link to 3D printable threaded rod and nut to fit your protectors to your vive controllers thanks to Lecter for the design.
I've not tried these printable threaded rods and nut myself so use at your own risk.
We used PETG filament, (2) 52 mm long, 5 mm nylon threaded rod as the top part of the protector is threaded and used nylon wing nuts to fasten the base. The rod and wingnuts are pennies on eBay.
The threaded rod should break away in the event that you strike a wall or furniture.