Senior TPU Film Process Engineer for PPF Scale-Up

XPEL; San Antonio (TX); On-site; USD 110,000 - 165,000; Full time

Job summary

XPEL, Inc. in San Antonio, TX, is seeking a Senior Process Engineer with direct TPU extrusion experience for Paint Protection Film (PPF) applications.

You will develop, optimize, and scale extrusion processes to produce optical-grade TPU films with high clarity, durability, and tight thickness control. The role focuses on process development, technical leadership, and continuous improvement using Lean/Six Sigma.

Qualifications

• Bachelors degree in Chemical, Polymer, Mechanical, or Materials Engineering required.
• 6+ years of progressive experience in process engineering with polymer films, coatings, or similar manufacturing.
• Hands-on expertise with manufacturing equipment, including process optimization, upgrades, and reliability improvements.
• Proven ability to lead complex troubleshooting with data-driven methods to optimize key parameters.
• Advanced proficiency in continuous improvement frameworks (Lean, Six Sigma) and project leadership.
• Strong analytical capabilities with statistical analysis, process capability, and hypothesis-driven problem solving.
• Experience leading cross-functional teams and influencing stakeholders across production, quality, and R&D.
• Willingness to travel 25–50% for multi-site operations and scale-up activities.

Responsibilities

• Develop, refine, and optimize TPU extrusion processes in collaboration with internal development groups.
• Establish and maintain process parameters to ensure consistent product quality.
• Lead root-cause analysis and corrective actions for deviations, scrap, and downtime.
• Implement continuous improvement initiatives using Lean, Six Sigma, or similar methodologies.
• Provide day-to-day technical support to production teams for extrusion lines.
• Troubleshoot melt temperature, die design, screw configuration, cooling, and downstream equipment.
• Partner with R&D to scale up TPU formulations from lab to production.
• Conduct extrusion trials, document results, and establish robust manufacturing processes.
• Collaborate with R&D to transition technologies to pilot and scale-up environments for successful commercialization.

Skills

TPU extrusion

Process development

Lean Six Sigma

Troubleshooting

Statistical analysis

Cross-functional leadership

Data-driven

Mentoring

Education

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

Job description

XPEL, Inc. in San Antonio, TX, is seeking a Senior Process Engineer with direct TPU extrusion experience for Paint Protection Film (PPF) applications.

You will develop, optimize, and scale extrusion processes to produce optical-grade TPU films with high clarity, durability, and tight thickness control. The role focuses on process development, technical leadership, and continuous improvement using Lean/Six Sigma.