To investigate the evolution of melting behavior during the steam-chest molding process of expanded polypropylene (EPP) bead, a differential scanning calorimetry (DSC) test involving fast heating, isothermal treatment, and fast cooling was used to simulate the bead foam processing. The EPP bead foam had two original melting peaks: a low melting peak, T-mlow, and a high melting peak, T-mhigh. A new melting peak, T-mi, was induced in the DSC curves, resulting from the heating process, when the treatment temperature was 80-150 degrees C. The T-mi was about 7 degrees C higher than the treatment temperature and tended to increase linearly with the increased treatment temperature. A new melting area and further a melting peak, T-mc, were observed in DSC curves, resulting from the cooling process, when the treatment temperatures were higher than 135 degrees C. The high sensitivity of the T-mi and T-mc to treatment temperature provided a clue to the actual temperature inside the mold during the steam-chest molding process. Different steam pressures were applied during EPP bead processing, and the melting behavior of molded EPP samples was measured to check the processing thermal history. A comparison study was done between the DSC simulations and the actual results to understand the melting behavior evolution of EPP bead foam during processing. Some fundamental issues in the steam-chest molding processing, such as the actual steam temperature, the temperature gradient across the mold cavity, and the accurate pressure parameter used to describe the actual processing temperature were also studied based on the DSC simulation.