Senior Analytical Engineer - Defect Analysis & Root Cause Investigation

• 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, 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.

• 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 Bachelor’s 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.