Thermoplastic foams nowadays are used in a wide variety of applications in the automotive, construction, and packaging industry because of their wide range of properties such as light weight, insulation properties, softness, excellent strength/weight ratio, material cost, energy absorption performance. However, there are still issues on the mechanical and other properties in use because of the foam structure. Recently, a new type of continuously coextruded multilayered PP film/PP foam composites was developed. The coextruded multilayered film/foam successfully mimicked the multilayer film/foam structure of natural cork with PP, which enhanced the compression properties due to multilayered film/foam structures. However, there is a lack of a clear understanding how to well optimize the structure-properties due to the insufficiency of the knowledge of rheology of materials related to branching degree of PP and molecular weights. In this thesis, therefore, the first part of thesis (Chapter 2) focuses on the understanding of the effect of strain-hardening on the BPPs film/BPPs foam morphology to optimize the multilayer structures. In Chapter 3, the mechanical properties and the dielectric properties of the multilayer BPPs film/BPPs foams (produced from Chapter 2) are characterized in terms of morphology. Mechanical properties of 16 and 32layer BPP2 film/BPP2 foams such as tensile and compression behaviors reveals the effect of the film/foam structure on the mechanical properties and gives a future idea. Dielectric properties of the biaxially oriented BPP2 foam/BPP2 films are affected by the film/foam morphology such as interfacial area. In Chapter 4 and Chapter 5, the research focuses on the morphology and mechanical properties of multilayer PPs film/PPs foam including flame retardant (FR) particles to achieve improving mechanical properties. Thus, in Chapter 4, the viscosity matched multilayer BPP2 film/BPP2 foams were investigated while in Chapter 5 the viscosity mismatched multilayer LPP film/BPP2 foams were examined. Both exhibited improved mechanical properties and the latter was further enhanced.In Chapter 6, the research emphasizes the effect of the film/foam structure of the multilayer LPP film/BPP2 foam with FR particles produced by Chapter 5 on flame retardancy via multilayer coextrusion, UL-94 test, cone-calorimeter test, and SEM/EDS analysis. The LPP film/BPP2 foam with FR particles exhibits better flame retardancy due to the efficient formation of char layer, caused by the alternating film/foam structure.