XPEL, Inc.

Senior Process Engineer

XPEL, Inc.$95K — $115K *
Manufacturing & Automotive
5 - 7 years of experience
Job Overview by Ladders

Qualifications

  • Bachelor's degree in Chemical, Polymer, Mechanical, Materials Engineering, or a related field.
  • 6+ years of progressive experience in process engineering, particularly with polymer films and coatings.
  • Hands-on expertise with manufacturing equipment, focusing on optimization and reliability improvements.
  • Ability to lead troubleshooting efforts using data-driven methodologies for process optimization.
  • Advanced skills in continuous improvement and problem-solving, with a history of project leadership.
  • Strong analytical skills, including experience with statistical analysis and process capability assessment.
  • Proven track record of cross-functional collaboration and influencing stakeholders across technical teams.
  • Experience managing multiple high-impact projects simultaneously in fast-paced environments.
  • Strategic mindset with strong attention to detail, aiming for process sustainability and cost optimization.
  • Experience mentoring junior engineers.

Responsibilities

  • Develop and optimize TPU extrusion processes in collaboration with lab teams.
  • Establish process parameters to maintain consistent product quality.
  • Lead root-cause analysis and corrective action for process deviations.
  • Implement continuous improvement initiatives using Lean or Six Sigma methodologies.
  • Provide technical support for production teams on extrusion lines.
  • Troubleshoot melt temperature issues, die design, and downstream equipment problems.
  • Partner with R&D to scale TPU formulations from lab to production.
  • Conduct extrusion trials and document results to establish solid manufacturing processes.
  • Collaborate with R&D to ensure technologies transition successfully to scale-up environments.
  • Analyze process data to monitor trends and enhance quality.

Benefits

  • Opportunity to work with cutting-edge TPU manufacturing processes.
  • Engagement in continuous improvement initiatives that affect product quality.
  • Collaborative work environment with R&D for product innovation.
  • Professional development opportunities, including mentorship of junior engineers.
  • Potential travel opportunities to support multi-site operations and learn from equipment vendors.
Full Job Description
Job Summary:

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.

Core Duties

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.


Basic Qualifications
  • 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.


About XPEL, Inc.

XPEL, Inc. is a leading provider of protective films and coatings for the automotive and architectural markets. The company's products are designed to protect against damage from rocks, debris, and other hazards, as well as to enhance the appearance of vehicles and buildings. XPEL's product portfolio includes paint protection films, window films, and ceramic coatings, among others. The company is headquartered in San Antonio, Texas, and has operations in the United States, Canada, and Europe.
Learn more about XPEL, Inc.
Size
709 employees
Market Cap
$1.5 billion
Industry
Net Income
$18.2 million
5 Year Trend
+38%
Revenue
$158.9 million
NASDAQ

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