We investigated the effect of PDLC layer thickness on morphology and electro-optical properties of plastic thermoset PDLC films with two nematic liquid crystal mixtures E7 and TNO623. The PDLC films were prepared on flexible ITO-PET supports by thermal PIPS phase separation method and the uniform film thickness was insured by plastic micro-spacers. We found that the PDLC layer thickness has a profound effect on micro-droplet morphology (dimension, number density and weight fraction) and electro-optical properties (off-state and on-state transmissions, switching voltages and response times).