James Gullberg A Portfolio Showcase
Portfolio

Projects

Mini 6 dof Arm
Personal Project · WIP

Mini 6 dof Arm

A mini 6-axis arm driven by stepper motors with custom 3D printed split ring planetary gearboxs and an inverted belt differential wrist with custom bearings, driven by low-cost stepper motors and TMC5150 drivers. Custom firmware was written in C for the STM32 MCU on an BTT Octopus board, to allow for full closed loop PID control using AS5048a encoders daisy-chained over SPI. The controller takes joint targets and returns joint states to a Raspberry Pi 5 streamed over CAN bus.

Stingray - Fixed Wing UAV
Queens Aerospace · 2025

Stingray - Fixed Wing UAV

A fully carbon fiber fixed-wing aircraft developed for the AEAC 2025 student competition to locate and map wildfires with an IR camera. Included a Pixhawk 6C flight computer, GPS and airspeed sensors, and stowed landing gear.

Crush - Quadcopter
Queens Aerospace · 2025

Crush - Quadcopter

A heavy-lift quadcopter made for the AEAC 2025 student competition to pick up and drop off water to aid in fighting forest fires.

Vex Robots - High Stakes
Vex Robotics · 2025

Vex Robots - High Stakes

As the Director of Mechanical, and in collaboration with other directors and project managers, we developed a pair of robots from scratch to compete in the 2025 VexU robotics season, receiving the Build Award at the World Championship in Dallas, which recognizes "a well-constructed robot that is built with a high degree of attention to detail in order to hold up to the rigors of competition."

Beam Profile Monitor Actuator
RMTL · 2024

Beam Profile Monitor Actuator

Made to allow remote control of a beam profile monitor in a Tandetron proton accelerator safely from the control room. Uses an air cylinder for actuation and communicates to the control box with ESP32s over a local network.

Cold Trap
RMTL · 2024

Cold Trap

Designed to be in an ultra-high vacuum chamber with the samples when they are being irradiated, the cold plate surface temperature reaches -25 degrees Celsius to condense any vapors to prevent contamination. This was a modification from a previous underperforming design, that was converted at a low cost with minimal new parts. A 10 to 15-degree reduction in temperature was observed.

Night Fury - VTOL UAV
Queens Aerospace · 2024

Night Fury - VTOL UAV

Together with a team, we created a fully carbon fiber VTOL aircraft with a 3m wingspan to compete in the Aerial Evolution Association of Canada Student Competition. My contributions include the 3D-printed molds for the carbon fiber skin, the tail and motor mounts, as well as many other small but important components.

VexU Differential Swerve Drive Module
VEX Robotics · 2024

VexU Differential Swerve Drive Module

Made for the 2024 VEXU competition, this module was one of the first in VEX history and gave us a huge competitive edge. It was powered from standard VEX hardware and printed with carbon fiber nylon on a Markforged printer. It incorporated novel design solutions like ring gears with built-in ball bearings and omni wheels that allow us to use it like a CVT. This year, our new module takes up 55% less volume in the robot, with improved reliability and durability.

Nalo Mix Pro
Academic Project · 2023

Nalo Mix Pro

This device can autonomously dispense set amounts of water and naloxone hydrochloride into 5 test tubes on a rotating turntable with an auger system and pump.
Designed on SolidWorks and fabricated from 3D-printed and laser-cut acrylic parts.

Differential Swerve Drive Module V1
Personal Project · 2023

Differential Swerve Drive Module V1

Originally designed for a swerve drive couch, this module is powered by two large brushless motors, and incorporates a planetary gearbox inside the wheel. Designed in Onshape and printed in PLA, with several of the metal parts being off the shelf.

Spring Launcher
Academic Project · 2023

Spring Launcher

Designed to accurately launch a spring at a certain angle and extension based on kinematic equations to land on a predetermined target for a grade 12 physics project. Modeled in Onshape and fully 3D-printed. Utilizing a lead screw for angle adjustment and a sliding trigger carriage with a ratchet system to hold the spring in place before launch. A metal pin actuated with a button releases the spring.

Ion Thruster
Academic Project · 2022

Ion Thruster

Was made to demonstrate the principles of an ion thruster and showcase corona discharge for my grade 12 chemistry final project. The design was made with Onshape and included replaceable cathodes and an adjustable anode on a track that would allow me to experiment to find the best setup. It was powered off of 4 1.5 V AA batteries with an off-the-shelf transformer.

3D Printed DC Motor
Academic Project · 2021

3D Printed DC Motor

A fully functional DC motor that was created to demonstrate motor principles for a grade 11 physics project. My teacher liked it so much he gave me a 100% in the course for it.

Nintendo Switch Apple Watch Charger
Etsy Product · 2022

Nintendo Switch Apple Watch Charger

This little stand was my best-selling product on Etsy. The design went through about a dozen iterations to optimize for consistent surface quality and ease of assembly.

AirTag Pokeball Keychain
Etsy Product · 2022

AirTag Pokeball Keychain

This keychain was another great selling product. It snapped together and hid an Apple AirTag inside to prevent thefts of bags and backpacks.

Adjustable iPad Stand
Etsy Product · 2022

Adjustable iPad Stand

This tablet stand integrated a rack and pinion system with a knob on the bottom for a continuously adjustable angle.

Remote Control Airplane V3
Personal Project · 2022

Remote Control Airplane V3

The goal for this aircraft was really slow and stable flight. Added leading-edge slats and permanently deployed flaps with 3D-printed parts to increase the stall angle, allowing for diabolically slow speeds.

Remote Control Airplane V2
Personal Project · 2021

Remote Control Airplane V2

The design goal for this airplane was to make it cheap and easy to construct and fly. Which is why I ditched the high-speed ducted fan for a propeller and went for a more conventional and stable airframe design. This aircraft was constructed almost entirely out of foam board and reused all the electronics.

Remote Control Flying Wing
Personal Project · 2019

Remote Control Flying Wing

The wings of this airplane were made from polystyrene foam cut with a homemade hot wire cutter and wooden dowels as spars. While the airframe was made up of 3mm and 6mm balsa wood sheets. It was propelled with a 75mm ducted fan and used mostly off-the-shelf electronic parts, except for a front FPV camera which was salvaged from a broken FPV quadcopter.