Yawman Flight faced the challenge of creating a unique flight simulator controller for its customer base of flight simulation enthusiasts and professionals in the aviation industry under significant time and budget constraints. The primary objectives were to develop a first-of-its-kind handheld flight simulator controller and complete the project rapidly and cost-effectively, without investing in costly injection molding tooling. Additionally, the team required high-quality surface finish and mechanical performance – so achieving injection molding-like quality quickly and affordably were critical to the success of the project.