Portfolio

The small selection of the design work I do.

Line of Work:

5015 Fan Duct Ender 3 Test Part Mario Sultan Designs
Industrial & Business-Related Products
5015 Fan Duct Adapter Bracket for Ender 3
Coffee Cup Bib Spill Prevention Invention 3d Model CAD 3d Printing Mario Sultan Designs
New Consumer Products & Prototypes
Anti-Spilling Coffee Cup Bib
Normal Force Finder Tool Education Physics Invention 3d Model CAD 3d Printing Mario Sultan Designs
Educational Aids & Learning Tools
Normal Force Finder – A Classroom Aid
Discuss Your Idea

Industrial/Business

PCB Board Holder Jig Engineering 3D Printed CAD Embedded Nuts Mario Sultan
PCB Board Holder Jig Engineering 3D Printed CAD Embedded Nuts Mario Sultan - exploded view
Radio unit base designed in CAD. 3D Modeling and 3D Printing.
Radio unit base designed in CAD. 3D Modeling and 3D Printing. Installed in the weatherproof case and with the radio and battery housing.
Replacing this expensive base with the 3D printed version.
These bases were being replaced with the new design.
Client provided mock-up of the design they wanted with the radio and battery housing laid on top.
Image & sketch by the client.
Radio unit base designed in CAD. 3D Modeling and 3D Printing.
ender 3 3d printer lcd screen holder base adapter relocation bracker 3d printed cad engineer mario sultan
Full rolling assembly of a v8 engine, drawing, CAD, 3D modeling. V8 Engine CAD 3D Model in PTC Creo Parametric
Full rolling assembly of a v8 engine, drawing, CAD, 3D modeling. V8 Engine CAD 3D Model in PTC Creo Parametric
My front screen door in relation to the handrails
I designed and built a sturdy, functional base to securely hold the Arduino, Garmin LiDAR sensor, LCD display, and all necessary wiring. This robust foundation enables me to prototype a device that measures the distance to the car ahead and detects changes in its speed, providing critical alerts when the vehicle slows down. The base is specifically engineered to support the components during testing, ensuring stability and ease of use throughout the development process.
I designed and built a sturdy, functional base to securely hold the Arduino, Garmin LiDAR sensor, LCD display, and all necessary wiring. This robust foundation enables me to prototype a device that measures the distance to the car ahead and detects changes in its speed, providing critical alerts when the vehicle slows down. The base is specifically engineered to support the components during testing, ensuring stability and ease of use throughout the development process.
Tesla Model 3 Console Bracket for Passing Wires Through. 3D printed.
Tesla Model 3 Console Bracket for Passing Wires Through. 3D printed
3d printed bracket printed using marble PETG.
3D CAD modeled bracket. Red color.
To reduce the rolling resistance of a full spool with the small axel, I created a universal fit adapter to fit every filament spool on this base's axel. Now it rolls easily. One thing to note: it was designed for manufacture, meaning I printed it in two parts the way I did to avoid supports and make it easy to use. Purple
To reduce the rolling resistance of a full spool with the small axel, I created a universal fit adapter to fit every filament spool on this base's axel. Now it rolls easily. One thing to note: it was designed for manufacture, meaning I printed it in two parts the way I did to avoid supports and make it easy to use.
To reduce the rolling resistance of a full spool with the small axel, I created a universal fit adapter to fit every filament spool on this base's axel. Now it rolls easily. One thing to note: it was designed for manufacture, meaning I printed it in two parts the way I did to avoid supports and make it easy to use.
Accurately made bracket (mating surface) for a random speaker my student had. Now that the base is accurate and the screws can be tightened into the plastic, I can design and build more practical parts, such as an enclosure or base. 3D printed in gray.
Accurately made bracket (mating surface) for a random speaker my student had. Now that the base is accurate and the screws can be tightened into the plastic, I can design and build more practical parts, such as an enclosure or base. 3D printed in gray.
Accurately made bracket (mating surface) for a random speaker my student had. Now that the base is accurate and the screws can be tightened into the plastic, I can design and build more practical parts, such as an enclosure or base. 3D model in CAD.
A 3D printer dimensioning and tolerancing gauge to physically baseline a printer and determine what size hole to dimension in CAD versus compensating in the slicer.
I had a network camera and wanted to mount it to my Ender 3, 3D printer so I didn't have to keep checking if my print was done. I created the bracket that mated with the camera I had and another bracket that kept the wire out of the way of the print bed and other moving components.
I had a network camera and wanted to mount it to my Ender 3, 3D printer so I didn't have to keep checking if my print was done. I created the bracket that mated with the camera I had and another bracket that kept the wire out of the way of the print bed and other moving components.
I had a network camera and wanted to mount it to my Ender 3, 3D printer so I didn't have to keep checking if my print was done. I created the bracket that mated with the camera I had and another bracket that kept the wire out of the way of the print bed and other moving components.
For my design, I opted for a toggle clamp to connect the top and bottom sections of the printer. Two side brackets were made to attach the sections together. This solution offers a fast and highly secure method for aligning the two portions effectively. My approach aims to reduce reliance on off-the-shelf components by incorporating more 3D-printed parts.
Inspired by Proper Printing's Folding Printer Project, I was impressed by their innovative folding mechanism. However, I envision a different design that offers greater security, ensuring better accuracy after folding and unfolding. My approach aims to reduce reliance on off-the-shelf components by incorporating more 3D-printed parts. MotionGen.io prototyping the foldable 3d printer.
Embedded nut into a 3D printed part.
A broken Samsung refrigerator door handle bracket.
Custom 3D printed plate to fix a broken Samsung refrigerator door handle bracket. Mirrored for both sides.
Custom 3D printed plate to fix a broken Samsung refrigerator door handle bracket. Epoxied to the bracket. Fixed!
Broken chain idler/tensioner on a Schwinn Tandem Bike.
3D printed a new idler/tensioner for a our Schwinn Tandem Bike.
Cap and reinforcement base for a hopper container from a machine.

Consumer Products & Innovation

Swiss Tech mini multitool case design CAD 3d model 3d print design mario sultan
iphone back pattern 3d printed business card holder cool design selfie mario sultan
white richmond map insulated water bottle mario sultan redesign cap close up with top
bottle cap redesign cad 3d model mario sultan reflection
Engagement Ring Wedding Band 3D Printed Notched Ring Fit CAD 3D Model Mario Sultan Design holding both rings
Engagement Ring Wedding Band 3D Printed Notched Ring Fit CAD 3D Model Mario Sultan Design both rings together on finger
Engagement Ring Wedding Band 3D Printed Notched Ring Fit CAD 3D Model Mario Sultan Design
3d printed cad insulated mug handle ergonimic grip engineer mario sultan front
Lever Corkscrew Wine Bottle Opener Base Designed Prusa 3D CAD 3D Printed Black Base Design Mario Sultan
3D Printed bike pump bracket. Red. Smiley face, happy!
I created a guard for my door's lock which has a lock/unlock feature which prevents the deadbolt and key from turning. When my dog gets excited, she jumps on the door and she has locked my out one too many times resulting in crawling through the window...No more!
I created a guard for my door's lock which has a lock/unlock feature which prevents the deadbolt and key from turning. When my dog gets excited, she jumps on the door and she has locked my out one too many times resulting in crawling through the window...No more!
A 3D-printed bib which is universal-fit for most throw-away Coffee Cups to prevent them from dripping.
Espresso Tamper 3D CAD 3D Printed Embedded Weight Cross Section Mario Sultan Design
3D Printed CAD Espresso Tamper Embedded Weight
3d printed prusa slicer spikes etsy order cosplay mario sultan
Toilet Flush Handle Adapter. Our toilet flush handle was sticking and wouldn’t return to the top position. In doing so, the water would not stop filling the bowl. The handle “arm” was dragging and grabbing onto the side of the toilet bowl. When I took the nut off and held the handle assembly at an angle so the arm is parallel to the bowl’s side, it stopped dragging and worked fine. Created an updated version once I realized that to install, you had to remove the nut and the chain in order to loop the part through (like a washer). Version 2.0 also had a slot so one wouldn’t need to take the nut or the chain off and I included a tab to help grip the piece while tightening the nut. A "T" label affordance was added to the top to distinguish the top from the bottom.
3D Printed External Hard Drive Drop-Protection Guard. Needed a way to protect my Seagate external hard drive. Printed two of the same "caps" and done!
You’re probably wondering…why not simply clip your pen or highlighter to your book? If you’re anyone like me, you write a lot in a book and you prefer to read, when standing or sitting on the couch, or even on the toilet. So instead of setting my pen down on my chest or my ear, I designed an printed a holder that clips into any book and hold a pen and highlighter. 3D Printed Book Pen Holder with Steve Jobs by Walter Isaacson's book
You’re probably wondering…why not simply clip your pen or highlighter to your book? If you’re anyone like me, you write a lot in a book and you prefer to read, when standing or sitting on the couch, or even on the toilet. So instead of setting my pen down on my chest or my ear, I designed an printed a holder that clips into any book and hold a pen and highlighter. 3D Printed Book Pen Holder with Steve Jobs by Walter Isaacson's book
You’re probably wondering…why not simply clip your pen or highlighter to your book? If you’re anyone like me, you write a lot in a book and you prefer to read, when standing or sitting on the couch, or even on the toilet. So instead of selling my pen down on my chest or my ear, I designed an printed a holder that clips into any book and hold a pen and highlighter. 3D Printed Book Pen Holder with Steve Jobs by Walter Isaacson's book
Thumb book page holder, black, modern, curvy, with my thumb. 3d printed
Anti-Escape Cord Holder This was a simple solution to a rather large inconvenience of mine. Of course, it’s very specific to my laptop cord; however I am working on a more generalized solution for any cord (even USBs) and for multiple desks. I like to add personal flares to my designs that either stimulate other ideas, inspire me, or simply make me smile. Always Create! Cheers.
Solving the pesky bookshelf gap! A custom-designed bracket keeps books upright and secure, combining function and style. 3D printed bracket.
Solving the pesky bookshelf gap! A custom-designed bracket keeps books upright and secure, combining function and style. 3D printed bracket.
T-shirt Glasses Holder. 3D printed blue sunglasses hook which can be mounted on a wall and hold your glasses/sunglasses.
This was one project I have been putting off for a long time. You would think that I would have chosen a different coffee cup or designed something by the third time my coffee spilled all over the car console. But no, I have been dealing with spilt coffee or a precarious grip on my mug while driving for over a year now. It wasn’t until my design-something-new-everyday exercise that I decided to finally design something for this huge inconvenience of mine.
This was one project I have been putting off for a long time. You would think that I would have chosen a different coffee cup or designed something by the third time my coffee spilled all over the car console. But no, I have been dealing with spilt coffee or a precarious grip on my mug while driving for over a year now. It wasn’t until my design-something-new-everyday exercise that I decided to finally design something for this huge inconvenience of mine.
Cool business card holder made of PETG marble filament with my logo on it.
Halloween Mask Based on AI Image. I had the privilege of working on my first custom build as a gift for someone’s husband back Fall of 2023. She asked me to physically create a mask based on this AI generated image she created. It was a great project that involved lots of surface modeling and therefore lots of fine tuning!
Halloween Mask Based on AI Image. I had the privilege of working on my first custom build as a gift for someone’s husband back Fall of 2023. She asked me to physically create a mask based on this AI generated image she created. It was a great project that involved lots of surface modeling and therefore lots of fine tuning! This is an image of the part where the strap attaches to,
Halloween Mask Based on AI Image I had the privilege of working on my first custom build as a gift for someone’s husband back Fall of 2023. She asked me to physically create a mask based on this AI generated image she created. It was a great project that involved lots of surface modeling and therefore lots of fine tuning!
Halloween Mask Based on AI Image I had the privilege of working on my first custom build as a gift for someone’s husband back Fall of 2023. She asked me to physically create a mask based on this AI generated image she created. It was a great project that involved lots of surface modeling and therefore lots of fine tuning!
3D Printed Pocket Pen Cover. I was tired of marking my pants with my gel pens. Used red PLA filament.
3D Printed Pocket Pen Cover. I was tired of marking my pants with my gel pens. Used red PLA filament.
Shirt Neck Button Extender
Shirt Neck Button Extender
Dresser Drawer Gap Fix - simple 3d printed black washers/spacers. Wayfair and Ikea furniture sucks. Amazon makes cardboard boxes that are stronger. Anyways, the wooden sides were bending and therefore causing a significant gap between the drawers and the side rails, so they kept falling. Simple solution fixed the problem. I should send these to the manufacturer.
Dresser Drawer Gap Fix - simple 3d printed black washers/spacers. Wayfair and Ikea furniture sucks. Amazon makes cardboard boxes that are stronger. Anyways, the wooden sides were bending and therefore causing a significant gap between the drawers and the side rails, so they kept falling. Simple solution fixed the problem. I should send these to the manufacturer.
Cristo Rey Richmond High School. A teacher leading an activity for our seniors (class of 2023) asked me to create a chess piece that had the text "ONE MORE MOVE" printed on the side. The message was that we all have one more move to make, no matter where we end up in the game. Printed 60 of them. It was a wonderful retreat.
Cristo Rey Richmond High School. A teacher leading an activity for our seniors (class of 2023) asked me to create a chess piece that had the text "ONE MORE MOVE" printed on the side. The message was that we all have one more move to make, no matter where we end up in the game. Printed 60 of them. It was a wonderful retreat.
Chopstick Trainer/Bracket. I want to eat my sushi and enjoy it, without looking like a fool.
3D Printed a Ender 3 V2 Neo 3D Printer LCD Cap - "Keep It Simple & Stupid" in blue.
3D printed watch holder, black with a hexagonal pattern on the side. With Garmin watch attached.
3D printed watch holder, black with a hexagonal pattern on the side.
The minion with the wild hair and the rubber duck were both .stl files that a dad sent me, asking if I could combine the two together for his son. His son was obsessed with purple, minions and rubber duckies so he wanted to earn Dad of the Year by getting this made for his son.
Lego-inspired bowtie, blue.
Modern black bowtie with diagonal modern cuts.
Modern black bowtie with hexagonal cuts.
Modern bowtie with hexagonal cuts printed with wood PLA filament.
Lego-inspired bowtie, green, with strap installed.
Whiteboard sketch of a bowtie and a robotic arm.
Blue 3d printed bow-tie I used to wear as a teacher.
Screen Door Holder. My front door is quite annoying in that it closes so fast behind you. You almost need to jump in sort of like Indiana Jones just to avoid the door hitting your heel. But the real reason for wanting to create something comes from bringing my bike in and out of the house. Not only is this door holder cute, it also slides forwards and backwards, remaining on the railing to be used whenever we need. The hook-like features on the ends keep it from sliding off the square tubing which gives it a hard stop.
Screen Door Holder. My front door is quite annoying in that it closes so fast behind you. You almost need to jump in sort of like Indiana Jones just to avoid the door hitting your heel. But the real reason for wanting to create something comes from bringing my bike in and out of the house. Not only is this door holder cute, it also slides forwards and backwards, remaining on the railing to be used whenever we need. The hook-like features on the ends keep it from sliding off the square tubing which gives it a hard stop.
Nissan car key fob with a broken loop. I 3D modeled and 3D printed a case that encloses the key and gets glued together so that it can be clipped to a keychain again.
Nissan car key fob now with the 3D modeled and 3D printed case, enclosed and fixed.
A student in my class came to me complaining that he keeps losing his car keys. After asking him why, he proceeds to pull out one loose key. A few hours of measuring, modeling, printing and prototyping, we have a solution.
3d printed sponge holder CAD model 3d model
3d printed sponge holder on sink with sponge

Education

Created a 3D printed plumb bob to use during labs in my physics classroom. I created two version - one which uses a marble and another which is solid.
Created a 3D printed plumb bob to use during labs in my physics classroom. I created two version - one which uses a marble and another which is solid.
Created a 3D printed plumb bob to use during labs in my physics classroom. I created two version - one which uses a marble and another which is solid.
A component vector finding tool. 3D printed, black.
Orange 3D printed plumb bob with the Fg (Force of gravity) label on it to showcase the direction of the gravity vector during physics demonstrations.
Purple 3D printed plumb bob with the Fg (Force of gravity) label on it to showcase the direction of the gravity vector during physics demonstrations.
The Normal Force Finder 2000 is a tool I used with my physics students to help them visualize normal forces on different surfaces. It was helpful during many demos.
3D Printed Mystery box activity. It's 3D printed rectangular box with different fin designs on the inside and a marble. This one has a circle and 2 marbles.
3D Printed Mystery box activity. It's 3D printed rectangular box with different fin designs on the inside and a marble. This one has 4 fins on the corners and one marble.
3D Printed Mystery box activity. It's 3D printed rectangular box with different fin designs on the inside and a marble. This one has two boxes inside it with a channel in the middle and 1 marble.
3D Printed Mystery box activity. It's 3D printed rectangular box with different fin designs on the inside and a marble. This image is of it enclosed with the cap. The cap says "Mystery Box."
DIY Physics demo tool. A 3D printed golf ball launcher and dropper. I built it using a gate latch which is zip tied to the custom base I designed. one golf ball lays on a platform and gets launched while the other has the gate latch rod inside of it and gets dropped (golf ball with a hole). The whole platform attaches to a chemistry clamp stand.
DIY Physics demo tool. A 3D printed golf ball launcher and dropper base. This is the CAD image.
DIY Physics demo tool. A 3D printed golf ball launcher and dropper. I built it using a gate latch which is zip tied to the custom base I designed. one golf ball lays on a platform and gets launched while the other has the gate latch rod inside of it and gets dropped (golf ball with a hole). The whole platform attaches to a chemistry clamp stand.
A 3D Modeled and 3D Printed Free body diagram, FBD, practice activity for Physics students. This image is it with a purple base and a orange cap. Intricate inner designs allows for the vectors to be placed at angles too.
A 3D Modeled and 3D Printed Free body diagram, FBD, practice activity for Physics students. This image is the base with the cap. here we also have the force vectors and their letter labels (normal force, friction force, gravity).
Class Rings for Cristo Rey Richmond High School, Classes of 2023 and 2024. I made class rings of every size for all the seniors to have.
Class Rings for Cristo Rey Richmond High School, Classes of 2023 and 2024. I made class rings of every size for all the seniors to have.
Class Rings for Cristo Rey Richmond High School, Classes of 2023 and 2024. I made class rings of every size for all the seniors to have.
Cristo Rey Richmond High School Athletics Game PassesThe Athletics director and fellow teacher asked me to create 3D printed game pass cards for the season.
Custom Ornaments for Cristo Rey Richmond High School. Commissioned to create ornaments for our donors. Printed the golden inserts separately and popped them into place. Was given one week to design and print complete them.
Custom Ornaments for Cristo Rey Richmond High School. Commissioned to create ornaments for our donors. Printed the golden inserts separately and popped them into place. Was given one week to design and print complete them.

Hobbies

Swiveling Bike Mirror Handlebar Bracket The bracket that came with the mirror which fits in the end of the handlebar would slip out as I'm riding and the bar is vibrating. So I 3D Printed a more permanent solution which I've been using for 2.5 years so far. I had to print it in PETG because it kept loosening when I made it in PLA and stored in my shed. Also made an end cap on the other side because those pesky things keep falling out.
Swiveling Bike Mirror Handlebar Bracket The bracket that came with the mirror which fits in the end of the handlebar would slip out as I'm riding and the bar is vibrating. So I 3D Printed a more permanent solution which I've been using for 2.5 years so far. I had to print it in PETG because it kept loosening when I made it in PLA and stored in my shed. Also made an end cap on the other side because those pesky things keep falling out.
Swiveling Bike Mirror Handlebar Bracket The bracket that came with the mirror which fits in the end of the handlebar would slip out as I'm riding and the bar is vibrating. So I 3D Printed a more permanent solution which I've been using for 2.5 years so far. I had to print it in PETG because it kept loosening when I made it in PLA and stored in my shed. Also made an end cap on the other side because those pesky things keep falling out.
Swiveling Bike Mirror Handlebar Bracket The bracket that came with the mirror which fits in the end of the handlebar would slip out as I'm riding and the bar is vibrating. So I 3D Printed a more permanent solution which I've been using for 2.5 years so far. I had to print it in PETG because it kept loosening when I made it in PLA and stored in my shed. Also made an end cap on the other side because those pesky things keep falling out.
Swiveling Bike Mirror Handlebar Bracket The bracket that came with the mirror which fits in the end of the handlebar would slip out as I'm riding and the bar is vibrating. So I 3D Printed a more permanent solution which I've been using for 2.5 years so far. I had to print it in PETG because it kept loosening when I made it in PLA and stored in my shed. Also made an end cap on the other side because those pesky things keep falling out.
Blue 3d printed Kayak Pad Eye Deck Hoops printed in two different orientations.
Orange whitewater Hydra kayak with the orange 3D modeled and 3D printed fin that requires you to ratchet strap it to the hull.
Orange 3D modeled and 3D printed fin for a whitewater Hydra kayak. This design requires you to ratchet strap it to the hull via a small slot on the bottom near the base.
Created a skeg bracket that accommodates paracord to stow and deploy the skeg from the kayak while underway. 3D modeled in CAD.
Created a skeg bracket that accommodates paracord to stow and deploy the skeg from the kayak while underway. 3D printed in blue.
Created a skeg bracket that accommodates paracord to stow and deploy the skeg from the kayak while underway. 3D printed in blue.
Created a skeg bracket that accommodates paracord to stow and deploy the skeg from the kayak while underway. 3D printed and assembled with skeg with orange paracord.
Created a skeg bracket that accommodates paracord to stow and deploy the skeg from the kayak while underway. Sketch on whiteboard
Created a skeg bracket that accommodates paracord to stow and deploy the skeg from the kayak while underway. Sketch on whiteboard with annotations.
Created a skeg bracket that accommodates paracord to stow and deploy the skeg from the kayak while underway. 3D modeled in CAD.