A modified concept for the generation of partially crosslinked expanded PP-films and -sheets, useable in automotive industry, is presented. The paper describes in detail an optimized formulation window for the organosilane crosslinking of the selected PP-copolymers, an adequate plant design for the realization of this innovative processing concept as well as approved process parameters. As derived from experimental studies, gel content and the amount of blowing agent seem to be the most essential parameters with regard to foam structure, foam density and cell size homogeneity.