UPDATE: i have a kickstarter going on this project so i can offer higher qaulity prints to people who would like to purchase the case/pcb/buttons over making their own. See this link https://www.kickstarter.com/projects/1088100966/pigear-handheld-gaming-system-20
This version is an expansion on the 2.8 inch version. The internal components besides the screen are the same. The added features on this one are that you have an external usb to connect a keyboard, or joystick to, and there is enough space to use 2 cylinder batteries to maximize play time. This design was inspired by the Sega Game Gear, and closely matches its size in both overall dimensions, and screen size. The idea was to make a better version of the pigrrl 2 that was so uncomfortable to hold. The improvements are that it has increased battery capacity, available hdmi, and eliminated the awful speaker hum that the pigrrl 2 had. This design incorporates a teensy for the controls so you have true analog for the joystick instead of just a dpad function like other projects. basically i took all the features i liked from other projects, took out the ones i didnt, and added what i thought should be there. I look forward to more designs in the future, and i hope that this one being released freely increases the interest in it.
Im not sure how well the 3d printed 6 button plate will work and i dont have one for the dpad or start/select buttons. This design was intended to use a set of pcb's i designed, and can be purchased rather cheap ($10) for all 3 boards. http://miniarcademachines.com/product/pcb-boards-for-the-5-inch-pigear/
The other items you will need are as follows:
1x - Raspberry Pi 3 - Model B
1x - Adafruit Mono 2.5W Class D Audio Amplifier - PAM8302
1x - Breadboard-friendly SPDT Slide Switch (check measurements before ordering, i use non standard switches)
1x - Lithium Ion Polymer Battery - 3.7v 2500mAh (cylinder type, look like AA)
2x - Mini Metal Speaker w/ Wires - 8 ohm 0.5W
1x - PowerBoost 1000 Charger (500 will work with using a smaller screw)
1x - 16GB sandisk or samsung class 10 SD/MicroSD Memory Card with retropie/attract front end (link can be provided for a download because its real tricky getting the lcd to work)
1x - 5 in TFT lcd for raspberry pi (waveshare brand with holes is what i use, but you may find other cheap ebay ones that might work)
6x - 6mm Tactile Button switches
6x - 12mm Tactile Button switches (the kind with a keycap that is removable)
10x - #4-40 3/8 machine screws
4x - #2-56 3/8 machine sccrews
1x - ribbon cable to cut up for jumper wire connections, and possibly 22 gauge for connecting the analog stick
speed for first layer was 40mm/sec and the rest was 60-80mm/sec. My printer runs real hot so i cant recommend a temp. the zip file attached is the teensy code for the controller setup. You will need it!
This design started in adobe illustrator, then was imported as a dxf in solidworks and saved as an stl. I used the makerbot software for printing prep.