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Karl Nilssen, EIT
(651) 334-1663     


Bachelor of Science in Aerospace Engineering, Cum Laude
     Embry-Riddle Aeronautical University, Prescott, AZ. GPA: 3.64, Completed in May 2011.
Engineer-in-Training Certification, Completed in spring 2011
Private Pilot Certification, Completed in August 2006. Current flight review in June 2011.


Active and Passive Flow Control
Aerodynamic Analysis
Aerodynamic Testing
ANSYS Finite Element Analysis
AutoDESK Inventor
Athena Vortex Lattice (AVL)
Blade-Element-Momentum Analysis
CATIA V5 (Part Design, Assembly, Generative Shape, Drafting, DMU Kinematics, Knowledgeware, General Structural Analysis and Sheet Metal Design)
Code of Federal Regulations Certification Experience
EASA Technical Implementation Procedures
FAA Regulation Knowledge
Hands on Testing Experience
LabVIEW Controls
LabVIEW Data Acquisition
MATLAB Programing
Microsoft Office Suite (Word, Excel, PowerPoint, Outlook, Project, Access)
Technical Report Writing
Test Data Analysis & Presentation

Transport Canada ImplementationProcedures for Airworthiness
Wireless Aircraft System Certification





Contract Airworthiness Engineer
Sikorsky Aircraft, Stratford, CT
Mar 2011 - Present
Review relevant Federal Regulations, primarily 14 CFR Part 29, and develop the appropriate certification requirements, plans and reports necessary to demonstrate regulatory compliance for new design projects.

-Coordinated certification projects including major airframe upgrades and drive system component upgrades.

-Coordinated certification of a landing gear re-analysis and component replacement time revision.

-Author and submit an average of one certification plan and one certification report per month.

-Prepare and submit EASA and Transport Canada validation requests for FAA certified designs.

-Tracked, processed, filed and maintained FAA documentation required for certification.

-Mange all certification projects for the Materials & Process Group.

-Responsible for certifying new materials on multiple rotorcraft simultaneously.

-Advise design groups on the analysis and testing requirements of aircraft modifications.

-Recovered significant backlog of aircraft repair approval documentation and reduced turnaround to 2 weeks.

-Prepared FAA familiarization presentations using Microsoft Office PowerPoint

Contract Engineering Technician
Goodrich Aerodynamics & Tunnel Group, Burnsville, MN
Dec 2011 - Feb 2012
Rapidly developed test systems for the new altitude icing wind tunnel through scalable design from bench testing.

-Developed LabVIEW code with active feedback for running experimental test systems.

-Ice particle characterization and optimization through test data analysis with statistical methods.

Paid Undergraduate Research Assistant
Embry-Riddle Aeronautical University, Prescott, AZ
May 2010 - May 2011
Worked in the Embry-Riddle Aeronautical University wind tunnel facility performing aerodynamic research on synthetic jet actuators for active flow control. The work included the development of custom testing hardware, software and sensor systems.
Synthetic Jet Actuator Research Project
-Prototype design of jet actuator, gearbox, drive linkage, and jet nozzle.
-Coordinated with machinist staff to build the needed high precision components and create drafting documentation.
-Reduced rapid prototyping costs by 66% through innovative redesign methods incorporating multiple materials.
-Developed a test control and data acquisition system using a closed loop feedback system in LabVIEW 8.2.
-Preformed a test data analysis and preparation for publication using MATLAB and Microsoft Excel.
-Approved, pending Journal of Aircraft publication of Evaluation and Characterization of a Lateral Synthetic Jet Actuator with Dr. Lance Traub and Michael Sweet.
-The synthetic jet was effective at preventing stall even in massively separated flow cases.

CATIA Teaching Assistant
Embry-Riddle Aeronautical University, Prescott, AZ
Aug 2008 - May 2011
I worked as a classroom aid and lab monitor assisting students learn CATIA and basic aircraft design principles.
-Primary workbenches taught: Part Design, Assembly, Generative Shape and Drafting
-Developed strong communication skills involving complex computer aided design software and engineering concepts.


AIAA Design-Build-Fly Sub-Team Leader
Aug 2009 - Feb 2010
While participating in the American Institute of Aeronautics and Astronautics (AIAA), I led the CAD solid modeling team for the Design-Build-Fly competition. The CATIA model included each component in a larger assembly with material properties applied.
-RESPONSIBILITIES: Oversaw junior team members and assigned CAD and solid modeling tasks.
-ACTIONS: Organized CAD files and created the aircraft assembly model.
-RESULTS: Ensured cargo bay attachment design and the correct C.G. balance of the aircraft using solid models.

Kingfisher Landing Gear Mechanical Design
Aug 2010 - Dec 2010
Designed both the main and nose gear support of the conceptual design of the Kingfisher Reconfigurable Amphibious Airplane. Shock absorber load and sizing was first determined; followed be the mechanical design of the retraction geometry and placement on the aircraft.
-ACTIONS: Designed a retractable landing gear to CFR 14 Part 23 guidelines.
-ANALYSIS: Developed load predictions to determine landing gear shock absorber and tire sizing.
-RESULTS: A landing gear was designed that met safe operational requirements during landing, take-off and taxi.

Kingfisher Wind Tunnel Model Design
Dec 2011 - Feb 2011
Led the effort to create a high accuracy model of the Kingfisher Reconfigurable Amphibious Airplane to be used for aerodynamic testing. The model included the solid modeling of all aerodynamic surfaces for ABS plastic rapid prototyping and the steel strengthening substructure.
-RESPONSIBILITIES: Directed force balance and flow visualization wind tunnel testing to ensure test data accuracy.
-RESULTS: Test data was used to verify aircraft range, endurance and stall performance.

Aircraft Elevator Design and Drafting
Jan 2011 - May 2011  
Used CATIA V5 to model and draft a 1:2-scale E-glass horizontal tail section including each layer of composite. Each component was then drafted and overall assembly process drawings were developed to ANSI standards
-ACTIONS: Produced all assembly process drawings and documented assembly procedures.
-ACTIONS: Prepared technical documents and presentations for industrial review panels.
-RESULTS: The drawing package led to on time construction and a successful structural test to failure.

Optimum Vortex Generator Placement
Jan 2010 - May 2010
Researched vortex generators to be used as passive flow control on a 3D wing and 2D airfoil at low Reynolds Numbers. The design included a reconfigurable wing and re-useable test equipment. A complex data analysis was completed using MATLAB and Excel.
-ACTIONS: Designed and tested a reconfigurable wing and airfoil using splitter plates and a sting balance.
-ANALYSIS: Determined the effect on lift, drag, and moment coefficients, and the lift curve slope.
-RESULTS: Placement within a leading edge separation bubble on thick airfoils hinders stall vortex generator effectiveness

Cut-out Delta Wing Design
Aug 2009 - Dec 2009
Researched delta wing design and vortex formation in the presence of a trapezoidal mid-wing cutout. Simulated the flow using the Lamar vortex lattice code and compared experimental and theoretical data.
-ACTIONS: Designed and manufactured steel delta wings and aluminum equipment adapters for research testing.
-RESULTS: Aerodynamic data analysis determined the cutout resulted in an increased lift coefficient and a decreased drag coefficient when compared to a standard delta wing.


All codes were simulated in LabVIEW to ensure proper functionality before final experimental testing and verification.
Front panel Graphic User Interfaces (GUIs) were designed for ease of use by new users and minimal learning curves.

Wind Turbine Control Code
Aug 2010 - Dec 2010
LabVIEW 8.2 software was developed to support the construction of a small scale research wind turbine. The code implemented both pitch-to-feather and pitch-to-stall control methodologies and used the power output as a control feedback.
-CODE CAPABILITY: Controlled the turbine rotation speed based off power generation and acquired power data.
-RESULTS: The pitch angle of the turbine blades were successful controlled at low rotation speeds.

Wake Rake Data Acquisition and Drag Determination Code
Jan 2010 - May 2010
LabVIEW 8.6 code was developed to interface between a 30 sensor port pressure scanner and physical testing hardware. An integration method was incorporated into the code to determine drag instantaneously and data output was formatted for Excel.
-CODE CAPABILITY: Variation in probe spacing and wake rake angle were accounted for in the determination of drag.
-RESULTS: Code was tested and verified in the small student designed wind tunnel at ERAU.

Synthetic Jet Research Code
May 2010 - May 2011
LabVIEW 8.2 software created in support of aerodynamic testing of synthetic jet actuators. The code interpreted raw data from multiple sensors to practical measurements and used the information to process a feedback control loop running the experiment. The experimental data was also preprocessed and formatting to Excel for ease of data analysis.
-CODE CAPABILITY: Acquired multiple data streams simultaneously while processing a feedback control loop.
-SENSORS: 2 high frequency pressure transducers, 1 hotwire anemometer and 1 rotation sensor data streams were read.
-RESULTS: The code was used to acquire test data and led to a pending publication in the Journal of Aircraft.

6-Component Balance Data Acquisition Code
Jan 2010 - May 2010
LabVIEW 9.0 code was developed to read and process signals for an NK 6-component balance. The lift, drag and side force coefficients and the yaw, pitch and roll moment coefficients were calculated using additional user inputs.
-CODE CAPABILITY: Interpreted raw data signals and output usable aerodynamic coefficients in an Excel format.
-RESULTS: Code was verified with testing in the 1 x 1 suction wind tunnel at Embry-Riddle Aeronautical University.


AeroLab pyramidal force and moment balance, in-house designed sting balances at Embry-Riddle Aeronautical University, hotwire anemometer, high frequency response pressure transducers, rotation sensors, National Instruments A/D converters, Lynx motion servo/motor control board, brushless speed controllers, strain gages, accelerometers

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