Series X controller sharp edge under trigger

It's not the triggers themselves that are sharp. It's the plastic housing of the controller that the triggers go down into. The inner edges of the plastic hurt my fingers.

One small criticism I have is with the trigger buttons. When they're fully depressed, the controller body has a sharp edge the rubs against your fingers.

I have to say, I have the S and now the X, two controllers each.
All controllers make smoke at light pressure, ale had and have sharp edges and a, high-quality they do not look in contrast to the old of the 360.

Thanks for your post Mike. I am shocked at the downgrade in quality for next gen. I Also have an injury to first finger right hand, from the trigger. When pushed in, the exposed edge of the controller is so sharp. it has blistered and now cut in to the finger.
I Will be ringing xbox as this cant be right. A Third party controller, will probably put this to shame.

Not sure what you mean by outline exactly but I would guess that it's a combination of the Sharpness control being set too high and an Edge Enhancement feature being enabled. You should be able to locate those options under the Picture menu.