Principal R&D Engineer - TPU Chemistry and Processing

XPEL, Inc.; San Antonio (TX); On-site; USD 90,000 - 120,000; Full time

Job summary

XPEL, Inc. is seeking a Principal Research and Development Engineer to lead the development of core technologies for TPU/EPU polymers. The role involves overseeing fundamental research, optimizing processing parameters, and collaborating with various teams to advance product innovations.

The ideal candidate should possess a B.S. in Chemistry or a related field along with significant industrial experience, particularly in polymer systems and extrusion processes. Strong problem-solving skills and technical expertise are required.

Qualifications

• 8+ years industrial experience in polymer science or materials science.
• Experience with TPU/EPU synthesis and film extrusion.
• Strong understanding of processing variables affecting polymer morphology.

Responsibilities

• Lead research into TPU/EPU polymer architecture.
• Optimize formulation and processing for high clarity films.
• Develop testing methodologies to ensure product standards.

Skills

Polyurethanes knowledge

Optical polymer systems

Problem-solving

Education

B.S. in Chemistry or relevant field

Tools

DMA/DHR

FTIR

TGA

Job description

Job Summary

The Principal Research and Development Engineer will lead and oversee their respective area(s) of development of XPEL’s core technology.

Core Duties

• Lead fundamental research into TPU/EPU polymer architecture (soft/hard segment ratios, chain extenders, isocyanates) and their effects on optical, thermal, and mechanical performance.
• Correlate polymer chemistry with durability, weathering resistance, and long‑term stability.
• Establish lab‑scale extrusion and film casting protocols for transparent and optical‑grade films.
• Define critical process–performance relationships, including haze, tensile strength, elongation, tear resistance, and environmental durability.
• Optimize formulation and processing parameters for high clarity, low birefringence, and minimal defects.
• Build and maintain a competitive intelligence database of global TPU chemistries, extrusion processes, and film performance benchmarks.
• Conduct accelerated aging, optical, and mechanical testing to validate long‑term performance targets.
• Translate lab‑scale polymer synthesis and extrusion processes to pilot and full production scale.
• Collaborate with process engineers, manufacturing teams, and external partners to ensure successful technology hand‑off.
• Identify and protect intellectual property opportunities in TPU/EPU chemistries, extrusion processes, and film applications.
• Stay at the forefront of polyurethane and optical polymer science to drive continuous innovation.
• Provide robust technical solutions to new product development initiatives and lend support to sales and product management teams.
• Bridge the gap from bench‑scale testing to industrial manufacturing processes by taking a lead role in the scale‑up process.
• Develop plans and procedures for specifications & fabrication of components, integration of technologies, balancing cost & manufacturability.
• Serve as technical interface to vendors and manufacturers.
• Continue to improve upon existing process and product through research and development in the specific area of responsibility.
• Remain versed and up to date on polymer chemistry, extrusion and other emerging technologies in the film industry.
• Develop and execute testing methodology necessary to ensure products meet industry standards.
• Develop a roadmap for next‑gen product innovations and lead platform level programs.
• Other duties as assigned.

Basic Qualifications

• B.S. in Chemistry, Polymer Science, Materials Science, Chemical Engineering, or related field with 8+ years industrial experience.
• Strong background in polyurethanes, thermoplastic elastomers, and optical polymer systems.
• Proven hands‑on experience with TPU/EPU synthesis, film extrusion, and coating processes.
• In‑depth knowledge of structure–property mapping for polyurethane materials.
• Strong understanding of processing variables (temperature, shear, residence time) and their effects on polymer morphology and film performance.
• Proficiency with optical and mechanical testing: haze, gloss, tensile, elongation, modulus, durability, and weatherability.
• Familiarity with additives (stabilizers, antioxidants, UV absorbers) and their influence on film performance.
• Technical expertise in thermal, mechanical, and optical properties for polymer multilayer films using advanced analytical tools such as DMA/DHR, DSC, FTIR, TGA, GPC/MS, profilometer, etc.
• Track record of patent generation and/or publications in polyurethane or optical polymer fields.
• Demonstrated experience working with interdisciplinary teams to drive programs from concept to production/commercialization.
• Strong problem‑solving and data‑driven decision‑making ability.
• Strong understanding of design of experiments and corresponding data analysis.
• Excellent communication skills with the ability to explain complex technical concepts to non‑technical stakeholders.
• Proven record of innovation, IP contribution, and technical leadership.

Desired Qualifications

Advanced Degree preferred.

Equal Opportunity Statement

XPEL is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees.