Principal R&D Engineer - TPU Chemistry and Processing

XPEL Inc.•San Antonio, TX

53d•Onsite

About The Position

The Principal Research and Development Engineer will lead and oversee their respective area(s) of development of XPEL's core technology.

Requirements

B.S in Chemistry, Polymer Science, Materials Science, Chemical Engineering, or related field with 8+ industrial experience
Strong background in polyurethanes, thermoplastic elastomers, and optical polymer systems.
Proven hands-on experience with TPU/EPU synthesis, film extrusion, and coating processes.
In-depth knowledge of structure-property mapping for polyurethane materials.
Strong understanding of processing variables (temperature, shear, residence time) and their effects on polymer morphology and film performance.
Proficiency with optical and mechanical testing: haze, gloss, tensile, elongation, modulus, durability, and weatherability.
Familiarity with additives (stabilizers, antioxidants, UV absorbers) and their influence on film performance.
Technical expertise in thermal, mechanical, and optical properties for polymer multilayer films using advanced analytical tools like DMA/DHR, DSC, FTIR, TGA, GPC/MS, profilometer, etc.
Track record of patent generation and/or publications in polyurethane or optical polymer fields.
Demonstrated experience working with interdisciplinary teams to drive programs from concept to production/commercialization
Strong problem-solving and data-driven decision-making ability
Strong understanding of design of experiments and corresponding data analysis
Excellent communication skills with the ability to explain complex technical concepts to non-technical stakeholders
Proven record of innovation, IP contribution, and technical leadership
In-office role

Nice To Haves

Advanced Degree preferred

Responsibilities

Lead fundamental research into TPU/EPU polymer architecture (soft/hard segment ratios, chain extenders, isocyanates) and their effects on optical, thermal, and mechanical performance.
Correlate polymer chemistry with durability, weathering resistance, and long-term stability.
Establish lab-scale extrusion and film casting protocols for transparent and optical-grade films.
Define critical process-performance relationships, including haze, tensile strength, elongation, tear resistance, and environmental durability.
Optimize formulation and processing parameters for high clarity, low birefringence, and minimal defects.
Build and maintain a competitive intelligence database of global TPU chemistries, extrusion processes, and film performance benchmarks.
Conduct accelerated aging, optical, and mechanical testing to validate long-term performance targets.
Translate lab-scale polymer synthesis and extrusion processes to pilot and full production scale.
Collaborate with process engineers, manufacturing teams, and external partners to ensure successful technology hand-off.
Identify and protect intellectual property opportunities in TPU/EPU chemistries, extrusion processes, and film applications.
Stay at the forefront of polyurethane and optical polymer science to drive continuous innovation.
Provide robust technical solutions to new product development initiatives and lend support to sales and product management teams
Bridge the gap from bench scale testing to industrial manufacturing processes by taking a lead role in the scale up process
Develop plans and procedures for specifications & fabrication of components, integration of technologies, balancing cost & manufacturability
Serve as technical interface to vendors and manufacturers
Continue to improve upon existing process and product through research and development in the specific area of responsibility
Remain versed and up to date on polymer chemistry, extrusion and other emerging technologies in the film industry
Develop and execute testing methodology necessary to ensure products meet industry standards
Develop a roadmap for next gen product innovations and lead platform level programs
Other duties as assigned