XPEL · 5 hours ago
Principal R&D Engineer - TPU Chemistry and Processing
San Antonio, TX
Full-time
Onsite
Lead/Staff
8+ years expXPEL is a company focused on core technology development, and they are seeking a Principal Research and Development Engineer to lead research in TPU/EPU polymer architecture. The role involves overseeing various aspects of polymer chemistry, process optimization, and collaboration with engineering and manufacturing teams.
Automotive
Responsibilities
Lead fundamental research into TPU/EPU polymer architecture (soft/hard segment ratios, chain extenders, isocyanates) and their effects on optical, thermal, and mechanical performance
Correlate polymer chemistry with durability, weathering resistance, and long-term stability
Establish lab-scale extrusion and film casting protocols for transparent and optical-grade films
Define critical process–performance relationships, including haze, tensile strength, elongation, tear resistance, and environmental durability
Optimize formulation and processing parameters for high clarity, low birefringence, and minimal defects
Build and maintain a competitive intelligence database of global TPU chemistries, extrusion processes, and film performance benchmarks
Conduct accelerated aging, optical, and mechanical testing to validate long-term performance targets
Translate lab-scale polymer synthesis and extrusion processes to pilot and full production scale
Collaborate with process engineers, manufacturing teams, and external partners to ensure successful technology hand-off
Identify and protect intellectual property opportunities in TPU/EPU chemistries, extrusion processes, and film applications
Stay at the forefront of polyurethane and optical polymer science to drive continuous innovation
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 by taking a lead role in the scale up process
Develop plans and procedures for specifications & fabrication of components, integration of technologies, balancing cost & manufacturability
Serve as technical interface to vendors and manufacturers
Continue to improve upon existing process and product through research and development in the specific area of responsibility
Remain versed and up to date on polymer chemistry, extrusion and other emerging technologies in the film industry
Develop and execute testing methodology necessary to ensure products meet industry standards
Develop a roadmap for next gen product innovations and lead platform level programs
Other duties as assigned
Qualification
Required
B.S in Chemistry, Polymer Science, Materials Science, Chemical Engineering, or related field with 8+ industrial experience
Strong background in polyurethanes, thermoplastic elastomers, and optical polymer systems
Proven hands-on experience with TPU/EPU synthesis, film extrusion, and coating processes
In-depth knowledge of structure–property mapping for polyurethane materials
Strong understanding of processing variables (temperature, shear, residence time) and their effects on polymer morphology and film performance
Proficiency with optical and mechanical testing: haze, gloss, tensile, elongation, modulus, durability, and weatherability
Familiarity with additives (stabilizers, antioxidants, UV absorbers) and their influence on film performance
Technical expertise in thermal, mechanical, and optical properties for polymer multilayer films using advanced analytical tools like DMA/DHR, DSC, FTIR, TGA, GPC/MS, profilometer, etc
Track record of patent generation and/or publications in polyurethane or optical polymer fields
Demonstrated experience working with interdisciplinary teams to drive programs from concept to production/commercialization
Strong problem-solving and data-driven decision-making ability
Strong understanding of design of experiments and corresponding data analysis
Excellent communication skills with the ability to explain complex technical concepts to non-technical stakeholders
Proven record of innovation, IP contribution, and technical leadership
In-office role
Preferred
Advanced Degree preferred
Company
XPEL
XPEL is a leading provider of protective films and coatings, including automotive paint protection film, surface protection film, automotive and commercial/residential window films, and ceramic coatings.
201-500 employees
H1B Sponsorship
XPEL has a track record of offering H1B sponsorships. Please note that this does not
guarantee sponsorship for this specific role. Below presents additional info for your
reference. (Data Powered by US Department of Labor)
Distribution of Different Job Fields Receiving Sponsorship
Represents job field similar to this job
Trends of Total Sponsorships
2025 (1)
2024 (1)
2023 (2)
2022 (1)
2021 (2)
Funding
Current Stage
Growth StageLeadership Team
Ryan Pape
President & CEO
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