James Gullberg A Portfolio Showcase

Projects

MP Substructure QC Rig, 2025

Mosaic Manufacturing

Developed a device to test proper Material Pod sub-assembly operation during the manufacturing process, and traveled to the contract manufacturer to train workers and ensure seamless integration into the assembly process. Dramatically cut down on QC-rejected Material Pods by catching faulty substructures prior to full assembly.

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Failed to Load Investigation, 2025

Mosaic Manufacturing

Developed a method of analyzing encoder metrics from a printhead with machine learning clustering algorithms to identify and categorize failure modes.

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Hardware Test Rigs, 2025

Mosaic Manufacturing

Developed several test rigs to aid in software and electrical testing and debugging. Allowed for simulation of full print workflows, and quick swapping of components.

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Stingray - Fixed Wing UAV, 2025

Queens Aerospace

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.

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Crush - Quadcopter, 2025

Queens Aerospace

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

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Vex Robots - High Stakes, 2025

Vex Robotics

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."

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Beam Profile Monitor Actuator, 2024

RMTL

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.

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Cold Trap, 2024

RMTL

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.

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Night Fury - VTOL UAV, 2024

Queens Aerospace

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.

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VexU Differential Swerve Drive Module, 2024

VEX Robotics

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.

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Nalo Mix Pro, 2023

Academic Project

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.

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Differential Swerve Drive Module V1, 2023

Personal Project

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.

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Spring Launcher, 2023

Academic Project

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.

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Ion Thruster, 2022

Academic Project

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.

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3D Printed DC Motor, 2021

Academic Project

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.

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Nintendo Switch Apple Watch Charger, 2022

Etsy Product

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.

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AirTag Pokeball Keychain, 2022

Etsy Product

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

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Adjustable iPad Stand, 2022

Etsy Product

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

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Remote Control Airplane V3, 2022

Personal Project

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.

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Remote Control Airplane V2, 2021

Personal Project

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.

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Remote Control Flying Wing, 2019

Personal Project

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.

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3D Printed 6-Axis Arm, WIP

Personal Project

Currently just CAD drawings of a split-ring planetary gearbox for the shoulder joint, but when completed it will be a nearly fully 3D-printed arm reinforced with carbon fiber rods, running on brushless motors and ODrives.

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