Senior Process Engineer

XPEL, Inc.; San Antonio (TX); On-site; USD 80,000 - 100,000; Full time

Job summary

XPEL, Inc., located in San Antonio, TX, is seeking a skilled Process Engineer focused on thermoplastic polyurethane (TPU) extrusion for Paint Protection Film applications. The candidate will be responsible for optimizing extrusion processes, ensuring product quality, and providing technical support to production teams.

The ideal candidate will possess a Bachelor’s degree and over six years of process engineering experience, with expertise in polymer films manufacturing and statistical analysis. This position involves leading process improvements and working collaboratively across teams.

Qualifications

• 6+ years of experience in process engineering, especially in manufacturing environments.
• Hands-on expertise in manufacturing equipment optimization.
• Experience in leading complex troubleshooting and continuous improvement projects.

Responsibilities

• Develop and optimize TPU extrusion processes with internal teams.
• Provide technical support to production teams and troubleshoot extrusion line issues.
• Analyze process data to identify trends and improve product quality.

Skills

Process engineering

Polymer films manufacturing

Statistical analysis

Lean Six Sigma methodologies

Problem-solving frameworks

Education

Bachelor’s degree in Chemical, Polymer, Mechanical, Materials Engineering

Tools

Manufacturing equipment

Job description

Job Summary

We are seeking a highly skilled Process Engineer with direct experience in thermoplastic polyurethane (TPU) extrusion for Paint Protection Film (PPF) applications. This role is responsible for working with organizations developing, optimizing, and scaling extrusion processes that produce optical-grade TPU films with exceptional clarity, mechanical durability, and surface performance. The ideal candidate understands the unique challenges of PPF manufacturing, including optical defects, gel control, surface uniformity, and tight thickness tolerances.

Core Duties

Process Development and Optimization: Develop, refine, and optimize TPU extrusion processes in collaboration with existing organizations in internal lab-based development. Establish and maintain process parameters to ensure consistent product quality. Lead root‑cause analysis and corrective actions for process deviations, scrap, and downtime. Implement continuous improvement initiatives using Lean, Six Sigma, or similar methodologies.

Technical Leadership, Support, and Troubleshooting: Provide day-to-day technical support to production teams for extrusion lines. Troubleshoot issues related to melt temperature, die design, screw configuration, cooling, and downstream equipment. Partner with R&D to scale up new TPU formulations and product designs from lab to production. Conduct extrusion trials, document results, and establish robust manufacturing processes. Collaborate with research and development teams as technologies transition to pilot and scale-up environments to ensure successful commercialization.

Quality, Safety, and Compliance Leadership: Develop and maintain process documentation, including work instructions, control plans, and standard operating procedures. Work closely with Quality to ensure compliance with customer specifications and industry standards. Analyze process data to identify trends and drive quality improvements.

Data Performance, Analytics, and Strategic Improvement: Monitor key process indicators (KPIs) such as yield, scrap rate, cycle time, and line efficiency. Use statistical tools to evaluate process capability and stability. Recommend and implement process automation or digital monitoring enhancements.

Basic Qualifications

• Bachelor’s degree in Chemical, Polymer, Mechanical, Materials Engineering, or a related field.
• 6+ years of progressive experience in process engineering, with strong exposure to polymer films, coatings, or similar manufacturing environments.
• Deep hands-on expertise with manufacturing equipment, including leading equipment optimization, upgrades, and reliability improvements.
• Proven ability to lead complex troubleshooting efforts, applying data-driven methodologies to resolve issues and optimize critical process parameters.
• Advanced proficiency in continuous improvement and problem-solving frameworks with demonstrated project leadership and measurable results.
• Strong analytical capabilities with experience in statistical analysis, process capability, and hypothesis-driven problem solving.
• Demonstrated leadership in cross-functional collaboration, with the ability to influence stakeholders and drive alignment across production, quality, and R&D teams.
• Experience managing multiple high-impact projects simultaneously in fast-paced manufacturing environments, with strong prioritization and execution skills.
• Strategic mindset with a strong attention to detail, focused on long-term process sustainability, scalability, and cost optimization.
• Proven track record of mentoring junior engineers and contributing to team development and technical growth.
• Willingness and ability to travel 25–50% to support multiple site operations, equipment vendors, and scale-up activities.

Equal Opportunity Employer

XPEL is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees. Since the day XPEL was founded, we’ve strived to provide the best possible products, services, and support for customers and installers alike. With a comprehensive array of offerings for automotive, watercraft, home, and office applications, there’s sure to be a solution to fit your needs.