The effects of processing conditions on the microstructure and properties of polypropylene/multiwalled carbon nanotube (PP/MWCNT) and polycarbonate/multiwalled carbon nanotube (PC/MWCNT) composites were studied. Samples of various MWCNT loadings were prepared by diluting commercial masterbatches. Different processing conditions were then used to systematically change the degree of nanotube alignment, from random to highly aligned. The crystallinity of the PP/MWCNT nanocomposites was found to go through a maximum as a function of nanotube content while the overall rate of crystallization increased. For the highly sheared microinjected PP/MWCNT samples well oriented crystals were formed. Electrical conductivity of the nanocomposites was improved by the presence of the crystalline structure; however, the high degree of nanotube alignment in the microparts resulted in a significant increase in the electrical percolation threshold. The PP nanocomposites exhibited mechanical properties significantly enhanced by nanotube loading; this effect was small in the case of the PC nanocomposites. POLYM. ENG. SCI., 51:992-1003, 2011. (C) 2011 Society of Plastics Engineers