Senior Analytical Engineer - Defect Analysis & Root Cause Investigation

Job Summary:

This individual will be supporting XPEL’s R&D activities while also lending support to analytical laboratory quality/Manufacturing teams as required across all of XPEL’s product portfolio and help drive efficiency and expand on current capability as appropriate to XPEL’s business needs. You must be able to thrive and succeed in an entrepreneurial environment, and not be hindered by ambiguity or competing priorities. The ideal candidate for this position is a detail-oriented individual with strong analytical and problem-solving skills, capable of understanding our products and acknowledging with ease its strengths and limitations with the intent to steer the development and evolution of our solutions. The candidate also has very strong communication skills and manages to communicate with a variety of stakeholders within XPEL.
The preferred location for this role will be at out of our office in San Antonio, TX. The Sr. R&D Engineer will report to the Director of Technology.

Core Duties:

• Lead and oversee the development of XPEL’s core technologies.
• Serve as the lab’s primary investigator for PPF/WPF manufacturing and field-return defects across all process stages, from raw material/melt prep through TPU extrusion, surface treatment, PSA lamination, topcoat cure, embossment, and slitting/storage.
• Apply a structured RCA workflow: define the defect signature, preserve paired defect/control samples, separate optical/chemical/mechanical origin, localize to a layer or interface, confirm chemistry and process physics, validate cure/molecular state, reproduce on a controlled trial, and lock the fix into SPC.
• Distinguish defect families (contamination, adhesion/interface, cure/crosslink, optical haze, thickness, migration/bloom, surface texture, thermal degradation, weathering, volatiles/moisture, mechanical, web handling) and select the right analytical pathway for each.
• Lead all surface analysis and imaging work for the team, owning method selection and technical sign-off across stereo, optical cross-section, and polarized light microscopy, SEM/SEM-EDS, AFM, 3D optical profilometry/confocal microscopy, white-light interferometry, XPS, and ToF-SIMS.
• Run thermal/molecular characterization (DSC, DMA, TGA, GPC/SEC, Karl Fischer), chromatography/mass spec (GC-MS, Py-GC/MS, LC-MS, ICP-OES/MS), mechanical/interfacial testing, and accelerated weathering to confirm chemistry and aging mechanisms.
• Work with Quality/manufacturing, and supply chain to identify and secure key strategic materials for existing and new PPF, coatings, and related technologies
• 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
• Knowledge build and assess risk & factor all relevant industrial process & material validation on product performance through its life cycle
• Develop plans and procedures for specifications & fabrication of components, integration of technologies, balancing cost & manufacturability
• Serve as technical interface to vendors and manufacturers
• Maintain meticulous documentation of work performed
• Provide leadership to the junior technical team
• Other duties as required.

Job Requirements:

• Strong technical background in polymer/material science, coatings, and associated technologies
• In-depth knowledge of coatings and/or adhesive chemistry, UV curing, photopolymerization applicable to industrial scale operations
• Demonstrated experience leading root cause investigations in a polymer film, coatings, or adhesives manufacturing environment, ideally roll-to-roll/continuous web processing, with proven depth leading surface analysis and imaging work for a team.
• Expert, hands-on command of surface analysis and imaging — SEM/SEM-EDS, AFM, 3D optical profilometry/confocal microscopy, white-light interferometry, XPS, and/or ToF-SIMS — sufficient to direct method selection and review others’ work.
• A background in thermal, mechanical, and optical properties for polymer multilayer films using advanced analytical tools like DMA/DHR, DSC, FTIR, TGA, profilometer, optical microscopy, etc.
• Knowledge in polymer film processing, roll to roll, sheet extrusion and related technologies
• Strong understanding of design of experiments and corresponding data analysis
• Experience working with domestic and international vendors
• Minimum of Bachelor’s degree in Chemistry, Materials Science, Polymer Science, Chemical Engineering, or related STEM field, with 5-10 years of relevant analytical/materials lab experience. Advanced degree (MS/PhD) preferred.
• Experience working with interdisciplinary teams to drive programs from concept to production/commercialization