TPU Film Process Engineering Lead

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. 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.