An extensive study on the peel strength between a polypropylene (PP) film and PP substrate fabricated using film insert injection molding technique was carried out through a 180degrees peel test. Injection molding conditions such as barrel temperature, injection speed and holding pressure were varied to gauge their effects on the mechanical and morphological properties. Morphological observations were made at the film-substrate interfacial regions by means of transmission electron microscopy (TEM). The injection molded products, with the films still attached, were subjected to bending and impact tests to determine if there is any relationship between film-substrate adhesion and bulk properties. Observation of the load-displacement curves during the peel test revealed three unique and interesting curves, corresponding to different peeling and film fracture mechanisms. Increases in injection speed, barrel temperature and holding pressure lead to increased bonding between the film and substrate surfaces. The enhancement of bonding between these two polymer surfaces could be attributed to polymer-polymer interdiffusion. Substantiating evidence from TEM, which shows the fading of the interface as the bond strengthens, further boosts the accuracy of this assumption. The hope that the films could contribute to enhancing bulk properties has been diminished since the bending properties appeared to be similar with or without the film attached. (C) 2004 Society of Plastics Engineers.