Senior Analytical Engineer - Defect Analysis & Root Cause Investigation

This individual will support XPEL’s R&D activities while also lending support to analytical laboratory quality and manufacturing teams across all of XPEL’s product portfolio. The role focuses on driving efficiency and expanding current capabilities to meet business needs. The ideal candidate thrives in an entrepreneurial environment, handles ambiguity and competing priorities, and possesses strong analytical, problem-solving, and communication skills.

Responsibilities

• 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, including raw material/melt prep, TPU extrusion, surface treatment, PSA lamination, topcoat cure, embossment, and slitting/storage.
• Apply a structured root cause analysis (RCA) workflow: define defect signatures, preserve paired defect/control samples, separate optical/chemical/mechanical origins, localize to layers or interfaces, confirm chemistry and process physics, validate cure/molecular state, reproduce on controlled trials, and implement fixes into SPC.
• Distinguish defect families (e.g., contamination, adhesion/interface, cure/crosslink, optical haze, thickness, migration/bloom, surface texture, thermal degradation, weathering, volatiles/moisture, mechanical, web handling) and select appropriate analytical pathways.
• Lead all surface analysis and imaging work, including method selection and technical sign-off across stereo, optical cross-section, 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.
• Collaborate with Quality, Manufacturing, and Supply Chain teams to identify and secure strategic materials for existing and new PPF, coatings, and related technologies.
• Provide robust technical solutions for new product development initiatives and support sales and product management teams.
• Bridge the gap from bench-scale testing to industrial manufacturing processes.
• Build knowledge, assess risk, and factor industrial process and material validation into product performance throughout its lifecycle.
• Develop plans and procedures for specifications, fabrication of components, and integration of technologies, balancing cost and manufacturability.
• Serve as the technical interface to vendors and manufacturers.
• Maintain meticulous documentation of work performed.
• Provide leadership to junior technical team members.
• Perform other duties as required.

Requirements

• Strong technical background in polymer/material science, coatings, and associated technologies.
• In-depth knowledge of coatings and/or adhesive chemistry, UV curing, and photopolymerization applicable to industrial-scale operations.
• Demonstrated experience leading root cause investigations in polymer film, coatings, or adhesives manufacturing, ideally in roll-to-roll/continuous web processing.
• Expert, hands-on command of surface analysis and imaging (e.g., SEM/SEM-EDS, AFM, 3D optical profilometry/confocal microscopy, white-light interferometry, XPS, ToF-SIMS) to direct method selection and review others’ work.
• Background in thermal, mechanical, and optical properties of polymer multilayer films using tools like DMA/DHR, DSC, FTIR, TGA, and profilometers.
• Knowledge of polymer film processing, roll-to-roll, sheet extrusion, and related technologies.
• Strong understanding of design of experiments (DOE) and corresponding data analysis.
• Experience working with domestic and international vendors.
• Minimum of a Bachelor’s degree in Chemistry, Materials Science, Polymer Science, Chemical Engineering, or a 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.

Preferred location: San Antonio, TX. Reports to the Director of Technology.