Open-cell materials are lightweight and multifunctional capable of absorbing acoustic energy and supporting mechanical load. The acoustic and mechanical performance of open-cell materials can be optimized through processing. In this article, the relationships between processing parameters and acoustic and mechanical performance are shown for polypropylene (PP) foams. PP foam samples are fabricated using a combined compression molding and particulate leaching process. The results from a parametric study showed that both salt size and salt to polymer ratio affect the acoustic and mechanical performance of open-cell PP foams. As salt size increases, cell size increased and cell density decreased. The salt to polymer ratio had opposite affect on cell density, and increasing the salt to polymer mass ratio increased the open-cell content. The airflow resistivity decreased significantly by increasing the cell size, which means that foam samples with smaller cell size have better sound absorption. When foam samples were thin, smaller cell sizes produced better sound absorption; however, as thickness of the sample increases, medium cell size offered the best acoustic performance. The compressive strength of the foams was increased by increasing the relative density. Acoustic performance results from the parametric study were compared to the Johnson-Allard model with good agreement. Finally, optimal cellular morphologies for acoustic absorption and mechanical performance were identified. (C) 2009 Wiley Periodicals, Inc. J Appl Polym Sci 116: 1106-1115,2010