Principal R&D Engineer - TPU Chemistry and Processing

About the Role

The Principal Research and Development Engineer will lead and oversee the development of XPEL’s core technology in TPU/EPU polymer architecture and related processes.

Responsibilities

• Lead fundamental research into TPU/EPU polymer architecture, including soft/hard segment ratios, chain extenders, and 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 support sales and product management teams.
• Bridge the gap from bench scale testing to industrial manufacturing processes by leading the scale-up process.
• Develop plans and procedures for specifications and fabrication of components, integration of technologies, balancing cost and manufacturability.
• Serve as technical interface to vendors and manufacturers.
• Improve existing processes and products through research and development in the specific area of responsibility.
• Remain current on polymer chemistry, extrusion, and emerging technologies in the film industry.
• Develop and execute testing methodology to ensure products meet industry standards.
• Develop a roadmap for next-generation product innovations and lead platform-level programs.
• Perform other duties as assigned.

Requirements

• B.S. in Chemistry, Polymer Science, Materials Science, Chemical Engineering, or related field with 8+ years of 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, and profilometer.
• 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.

Qualifications

• Advanced degree preferred.