Sr. Process Engineer

XPEL•San Antonio, TX

About The Position

We are seeking a highly skilled Process Engineer with direct experience in thermoplastic polyurethane (TPU) extrusion for Paint Protection Film (PPF) applications. This role is responsible for working with organizations developing, optimizing, and scaling extrusion processes that produce optical-grade TPU films with exceptional clarity, mechanical durability, and surface performance. The ideal candidate understands the unique challenges of PPF manufacturing, including optical defects, gel control, surface uniformity, and tight thickness tolerances.

Requirements

Bachelor’s degree in Chemical, Polymer, Mechanical, Materials Engineering, or a related field.
6+ years of progressive experience in process engineering, with strong exposure to polymer films, coatings, or similar manufacturing environments.
Deep hands-on expertise with manufacturing equipment, including leading equipment optimization, upgrades, and reliability improvements.
Proven ability to lead complex troubleshooting efforts, applying data-driven methodologies to resolve issues and optimize critical process parameters.
Advanced proficiency in continuous improvement and problem-solving frameworks with demonstrated project leadership and measurable results.
Strong analytical capabilities with experience in statistical analysis, process capability, and hypothesis-driven problem solving.
Demonstrated leadership in cross-functional collaboration, with the ability to influence stakeholders and drive alignment across production, quality, and R&D teams.
Experience managing multiple high-impact projects simultaneously in fast-paced manufacturing environments, with strong prioritization and execution skills.
Strategic mindset with a strong attention to detail, focused on long-term process sustainability, scalability, and cost optimization.
Proven track record of mentoring junior engineers and contributing to team development and technical growth.
Willingness and ability to travel 25–50% to support multi-site operations, equipment vendors, and scale-up activities.

Responsibilities

Process Development and Optimization Develop, refine, and optimize TPU extrusion processes in collaboration with existing organizations in internal lab-based development
Establish and maintain process parameters to ensure consistent product quality
Lead root-cause analysis and corrective actions for process deviations, scrap, and downtime.
Implement continuous improvement initiatives using Lean, Six Sigma, or similar methodologies.
Technical Leadership, Support, and Troubleshooting Provide day-to-day technical support to production teams for extrusion lines.
Troubleshoot issues related to melt temperature, die design, screw configuration, cooling, and downstream equipment.
Partner with R&D to scale up new TPU formulations and product designs from lab to production.
Conduct extrusion trials, document results, and establish robust manufacturing processes.
Collaborate with research and development teams as technologies transition to pilot & scale-up environments to ensure successful commercialization.
Quality, Safety, and Compliance Leadership Develop and maintain process documentation, including work instructions, control plans, and standard operating procedures.
Work closely with Quality to ensure compliance with customer specifications and industry standards.
Analyze process data to identify trends and drive quality improvements.
Data Performance, Analytics, and Strategic Improvement Monitor key process indicators (KPIs) such as yield, scrap rate, cycle time, and line efficiency.
Use statistical tools to evaluate process capability and stability.
Recommend and implement process automation or digital monitoring enhancements.