Senior Process Engineer

Benefits

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Not verified last checked Jun 13, 2026

Salary

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401(k) match

Listed Source: EMPLR_CONTRIB_INCOME_AMT. source Last checked Jun 13, 2026.

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About this role

Senior Process Engineer San Antonio, TX Job Summary: We are seeking a highly skilled Process Engineer with direct experience in thermoplastic polyurethane (TPU) extrusion for Paint Protection Film (PPF) applications. This role is responsible for working with organizations developing, optimizing, and scaling extrusion processes that produce optical-grade TPU films with exceptional clarity, mechanical durability, and surface performance. The ideal candidate understands the unique challenges of PPF manufacturing, including optical defects, gel control, surface uniformity, and tight thickness tolerances. Core Duties Process Development and Optimization Develop, refine, and optimize TPU extrusion processes in collaboration with existing organizations in internal lab-based development Establish and maintain process parameters to ensure consistent product quality Lead root-cause analysis and corrective actions for process deviations, scrap, and downtime. Implement continuous improvement initiatives using Lean, Six Sigma, or similar methodologies. Technical Leadership, Support, and Troubleshooting Provide day-to-day technical support to production teams for extrusion lines. Troubleshoot issues related to melt temperature, die design, screw configuration, cooling, and downstream equipment. Partner with R&D to scale up new TPU formulations and product designs from lab to production. Conduct extrusion trials, document results, and establish robust manufacturing processes. Collaborate with research and development teams as technologies transition to pilot & scale-up environments to ensure successful commercialization. Quality, Safety, and Compliance Leadership Develop and maintain process documentation, including work instructions, control plans, and standard operating procedures. Work closely with Quality to ensure compliance with customer specifications and industry standards. Analyze process data to identify trends and drive quality improvements. Data Performance,

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