Polypropylene homopolymer (PP) and a copolymer (P/E) were processed using the Reicofil® spunbonding line at the Textiles and Nonwovens Development Center of the University of Tennessee, Knoxville. The properties of the filament samples taken before thermal-bonding were determined through a variety of techniques such as differential scanning calorimetry, thermomechanical analysis, thermal deformation analysis and mechanical properties. The two process variables investigated, primary air temperature and throughput had a strong influence on the structure and properties of both the filaments and the bonded nonwovens. As the primary air temperature and throughput decreased, there was a tendency for decrease in filament diameter with a simultaneous increase in their crystallinity, birefringence and thermal stability. The copolymer filaments showed lower crystallinity and orientation for all the corresponding processing conditions.