Principal Process Engineer

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.