Principal R&D Engineer - TPU Chemistry and Processing

Job Summary:

The Principal Research and Development Engineer will lead and oversee their respective area(s) of development of XPEL's core technology.

Core Duties

* 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

Basic Qualifications

* 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

Desired Qualifications

* Advanced Degree preferred

XPEL is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees.