Principal Process Engineer, Film Extrusion

XPEL, Inc. (NASDAQ: XPEL), a leading supplier of automotive paint protection films, window films, ceramic coatings, and commercial/residential flat glass films, is currently seeking a Principal Process Engineer to join our team in San Atonio, TX.

Summary

XPEL is seeking a highly experienced Principal Process Engineer to lead the strategy, optimization, and scale-up of TPU film extrusion processes across our global manufacturing network. This role serves as the technical authority for extrusion operations, driving innovation from laboratory development through commercial production while ensuring world-class film quality, process stability, and operational excellence.

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.Experience in film extrusion, polymer processing, or specialty materials manufacturing. TPU and optical-film experience highly 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.

This position will have relocation assistance available within the United States.

Why XPEL?

No Tomorrow

We move with urgency, take action, and continuously pursue better outcomes. We don't wait for opportunities. We create them.

Humility

We have confidence in our abilities and humility in our approach. We learn, listen, and grow together.

Ownership & Accountability

We take responsibility for results, make decisions with integrity, and do what's right for our customers, teammates, and shareholders.

Inclusion & Belonging

We believe our best ideas emerge when people feel respected, valued, and empowered to contribute their unique perspectives.

Rewards & Recognition

We celebrate achievement, recognize contributions, and invest in the growth and success of our people.

Join Us

If you're excited by the opportunity to influence strategy, partner with executive leadership, engage directly with the investment community, and help drive the future of a high-growth public company, we'd love to hear from you.

Protect Everything. Including your next great career move.

XPEL, Inc. is an Equal Opportunity Employer. We celebrate diversity and are committed to creating an inclusive environment for all employees.