Nonisothermally fusion bonded butt joints were prepared by overmolding thermoplastic elastomers (TPEs) onto isotactic polypropylene (iPP) inserts in order to investigate the effect of processing conditions on the bond strength and interfacial microstructure. The mold temperature (T-m) was the most important factor for bond strength, as determined from interfacial mechanical tests. Extensive melting and recrystallization took place at the surface of the iPP insert at high T-m, promoted by migration of plasticizer from the TPE, whereas the original structure of the iPP remained intact at low T-m. Bond strengths of at least 50% of the cohesive strength of the TPE were nevertheless obtained at low T-m, suggesting intimate contact between the TPE melt and the iPP surface to be sufficient to provide useful adhesive bond strengths in these materials. The influence of pressure was less marked than the T-m, high pressures not being necessary to achieve intimate contact for the bonding times of about 5 s used here. However, the combination of a low bonding pressure with a high T-m typically led to poor quality bonds in thick specimens owing to uncompensated shrinkage during solidification, and voiding at the interface and in the melt zone of the iPP insert. POLYM. ENG. SCI., 58:E82-E92, 2018. (c) 2017 Society of Plastics Engineers