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.