Principal Process Engineer

XPEL; San Antonio (TX); On-site; USD 140,000 - 200,000; Full time

Job summary

XPEL, Inc. in San Antonio, TX, seeks a Principal Process Engineer to lead extrusion process strategy across internal and partner sites, driving lab-to-production scale-up for TPU films and related coatings.

You will define process standards, work with R&D on scale-up using DOE, monitor KPIs, and mentor engineers while coordinating with suppliers and manufacturers; relocation assistance within the United States is available.

Qualifications

• B.S. in Chemical, Polymer, Mechanical, or Materials Engineering (or related field) with 8+ years of process engineering experience.
• Hands-on TPU film or sheet extrusion experience; optical-grade or PPF films strongly preferred.
• Deep expertise in cast and/or blown film extrusion: screw and die design, melt filtration, drying, chill-roll casting, and winding.
• Strong grasp of how temperature, shear, residence time, and moisture affect TPU degradation, morphology, and film performance.
• Proven record of lab-to-production scale-up and of leading complex, data-driven troubleshooting.
• Advanced Lean/Six Sigma and statistical skills (DOE, SPC, Cp/Cpk) with measurable results; Black Belt preferred.
• Experience specifying and commissioning extrusion equipment and leading reliability improvements.
• Demonstrated cross-functional influence, multi-project leadership in multi-site environments, and mentoring of engineers.
• Travel: 25-50%.

Responsibilities

• Own TPU extrusion process strategy and roadmap across internal, toll, and acquired manufacturing sites.
• Define process–performance links between melt temperature, shear, residence time, moisture, and cooling and film haze, gels, birefringence, surface quality, and gauge.
• Set process standards for drying, filtration, screw and die design, casting, and inline inspection; lead equipment specification, FAT, and commissioning for new lines and upgrades.
• Partner with R&D to scale new TPU formulations from lab to pilot to production using DOE-driven trials, and own technology transfer packages (process windows, CTQs, control plans).
• Lead cross-site root-cause investigations into optical defects, gels, contamination, die lines, and gauge variation using 8D, DMAIC, and similar tools.
• Maintain PFMEAs, control plans, SOPs, and work instructions, and work with Quality to meet customer and industry specifications.
• Set SPC and Cp/Cpk targets, track KPIs (yield, scrap, OEE), and lead inline gauge, defect inspection, and digital monitoring initiatives.
• Drive Lean and Six Sigma improvement programs with measurable cost, quality, and throughput results.
• Mentor process engineers and technicians, and serve as technical interface to equipment vendors, resin suppliers, and contract manufacturers.
• Communicate strategy, risks, and results to production, quality, R&D, commercial, and executive stakeholders.

Skills

Extrusion

Scale-up

DOE

Lean Six Sigma

Statistical analysis

Education

B.S. in Chemical/Polymer/Mechanical/ Materials Eng

Tools

Python

JMP

Minitab

MES

Job description

XPEL, Inc. (NASDAQ: XPEL), a leading supplier of automotive paint protection films, window films, ceramic coatings, and commercial/residential flat glass films, is currently seeking a Principal Process Engineer to join our team in San Atonio, TX.

Summary

The Principal Process Engineer sets extrusion process strategy, leads lab-to-production scale-up across internal and partner sites, and builds the standards, data systems, and people that keep films clear, durable, and in tolerance

Core Duties

Process Strategy and Scale-Up

• Own TPU extrusion process strategy and roadmap across internal, toll, and acquired manufacturing sites.
• Define process–performance links between melt temperature, shear, residence time, moisture, and cooling and film haze, gels, birefringence, surface quality, and gauge.
• Set process standards for drying, filtration, screw and die design, casting, and inline inspection; lead equipment specification, FAT, and commissioning for new lines and upgrades.
• Partner with R&D to scale new TPU formulations from lab to pilot to production using DOE-driven trials, and own technology transfer packages (process windows, CTQs, control plans).
• Qualify new raw materials and suppliers for process impact and identify process IP with R&D and legal.

Troubleshooting, Quality, and Data

• Lead cross-site root-cause investigations into optical defects, gels, contamination, die lines, and gauge variation using 8D, DMAIC, and similar tools.
• Maintain PFMEAs, control plans, SOPs, and work instructions, and work with Quality to meet customer and industry specifications.
• Set SPC and Cp/Cpk targets, track KPIs (yield, scrap, OEE), and lead inline gauge, defect inspection, and digital monitoring initiatives.

Leadership

• Drive Lean and Six Sigma improvement programs with measurable cost, quality, and throughput results.
• Mentor process engineers and technicians, and serve as technical interface to equipment vendors, resin suppliers, and contract manufacturers.
• Communicate strategy, risks, and results to production, quality, R&D, commercial, and executive stakeholders.

Basic Qualifications

• B.S. in Chemical, Polymer, Mechanical, or Materials Engineering or related field with 8+ years of process engineering experience. Advanced degree preferred.
• Hands-on TPU film or sheet extrusion experience; optical-grade or PPF films strongly preferred.
• Deep expertise in cast and/or blown film extrusion: screw and die design, melt filtration, drying, chill-roll casting, and winding.
• Strong grasp of how temperature, shear, residence time, and moisture affect TPU degradation, morphology, and film performance.
• Proven record of lab-to-production scale-up and of leading complex, data-driven troubleshooting.
• Advanced Lean/Six Sigma and statistical skills (DOE, SPC, Cp/Cpk) with measurable results; Black Belt preferred.
• Experience specifying and commissioning extrusion equipment and leading reliability improvements.
• Demonstrated cross-functional influence, multi-project leadership in multi-site environments, and mentoring of engineers.
• Travel: 25-50%

Desired Qualifications

• Coextrusion and multilayer film experience (feedblock and multi-manifold dies), ideally in cleanroom or optical, display, or medical-grade settings.
• Working knowledge of TPU/EPU chemistry and additives (UV absorbers, HALS, antioxidants) and their behavior during processing.
• Familiarity with downstream PPF/film steps: coating, lamination, adhesives, and slitting.
• Proficiency with film characterization (haze, gloss, gauge, rheology, DSC, TGA, FTIR) and data tools (Python, JMP, Minitab, MES).
• Experience supporting international sites, toll manufacturers, or acquisition integration; patents or publications a plus.

This position will have relocation assistance available within the United States.

XPEL, Inc. is an Equal Opportunity Employer. We celebrate diversity and are committed to creating an inclusive environment for all employees.