Senior Analytical Engineer Defect Analysis & Root Cause Investigation

Job Summary:

This individual will be supporting XPELs R&D activities while also lending support to analytical laboratory quality/Manufacturing teams as required across all of XPELs product portfolio and help drive efficiency and expand on current capability as appropriate to XPELs business needs. You must be able to thrive and succeed in an entrepreneurial environment and not be hindered by ambiguity or competing priorities. The ideal candidate for this position is a detail-oriented individual with strong analytical and problem-solving skills capable of understanding our products and acknowledging with ease its strengths and limitations with the intent to steer the development and evolution of our solutions. The candidate also has very strong communication skills and manages to communicate with a variety of stakeholders within XPEL.
The preferred location for this role will be at out of our office in San Antonio TX. The Sr. R&D Engineer will report to the Director of Technology.

Core Duties:

• Lead and oversee the development of XPELs core technologies.
• Serve as the labs primary investigator for PPF/WPF manufacturing and field-return defects across all process stages from raw material/melt prep through TPU extrusion surface treatment PSA lamination topcoat cure embossment and slitting/storage.
• Apply a structured RCA workflow: define the defect signature preserve paired defect/control samples separate optical/chemical/mechanical origin localize to a layer or interface confirm chemistry and process physics validate cure/molecular state reproduce on a controlled trial and lock the fix into SPC.
• Distinguish defect families (contamination adhesion/interface cure/crosslink optical haze thickness migration/bloom surface texture thermal degradation weathering volatiles/moisture mechanical web handling) and select the right analytical pathway for each.
• Lead all surface analysis and imaging work for the team owning method selection and technical sign-off across stereo optical cross-section and 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.
• Work with Quality/manufacturing and supply chain to identify and secure key strategic materials for existing and new PPF coatings and related technologies
• 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
• Knowledge build and assess risk & factor all relevant industrial process & material validation on product performance through its life cycle
• Develop plans and procedures for specifications & fabrication of components integration of technologies balancing cost & manufacturability
• Serve as technical interface to vendors and manufacturers
• Maintain meticulous documentation of work performed
• Provide leadership to the junior technical team
• Other duties as required.

Job Requirements:

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

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