About this Principal Process Engineer role at XPEL
XPEL · Onsite · San Antonio, TX
Job 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.
XPEL is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees.
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