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The microcellular foam injection molding process for thermoplastic materials provides design flexibility and cost savings opportunities not found in conventional injection molding. This process allows for plastic part design with material wall thickness optimized for functionality. The combination of density reduction and design for functionality can result in material and weight savings of up to 20%. With the correct equipment configuration, mold design, and processing conditions, these microcellular voids are uniform in size and distribution. The use of microcellular foam molding provides significant reductions in cycle time, material consumption, injection pressure, and clamp tonnage. In this work, a physical foam molding process, MuCell, is applied to a polypropylene (PP) composite.