AbstractFibers spun from blends of small percentage of plastic grade polypropylene (HMPP) with fiber grade polypropylene (PP) are studied for drawing behavior. A factorial design of experiment is used for a two‐stage drawing process with variables, such as percent of HMPP component, first stage draw ratio and temperature, and second stage temperature. Optimization is carried out for breaking stress and modulus of drawn filaments. Breaking stress of up to 0.74 GPa and initial modulus of 7.34 GPa is possible by such an optimization process. These properties are observed for 6 HMPP blend composition. Heat setting of drawn filaments show little changes up to 140°C heat‐setting temperature. Large scale structural changes with rapid drop in mechanical properties is observed for 150‐160°C heat‐se
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