Meh its most likely a joke but the melting point of lego is pretty high. They are made from ABS plastic and my girlfriend was showing me someone used a lego mould for some metal casting.
There's some cool Lego CAD software out there you can use to prototype your designs. There's the official Lego Digital Designer, and many others using the ldraw open standard. I'd be interested in having a crack at making an OG Gameboy casing in Lego or a consolised Neo Geo MVS.
Patents aside, there's a simple issue with the 360's d-pad, and that's that the enclosure surrounding it prevents it from full movement (i.e. sometimes the d-pad hits the surrounding plastic and doesn't the movement doesn't get registered). This is responsible for most of the d-pad's poor responsiveness. I fixed it by gouging out a lot of the surrounding plastic, but really, when you need to take a fucking stanley knife and sandpaper to get a game controller working halfway decent, something is very, very wrong. It's still far from perfect. There are guides out there if anyone else wants to do the same.
i just hate that i can't do down, forward, punch without jumping around. easily one of the worst D-pads of all time. i'm thinking about getting a set of arcade sticks for the 360. though i'm not really sure what quality sticks are available...
I just bought a Hori DOA4 stick. I'll let you know how it is. I'm not mr fighter pro though. So far I know theres ones you can build, ones from Arcade in a box.com, the Hori soul calibur 4m doa4 and regular ones, and next year theres a hori Real arcade pro and SF4 sticks.