During film casting, molten polymer is extruded through a rectangular die and then cooled rapidly on a chill roll. Subsequent biaxial stretching can be employed to manipulate the film properties. In this work, we investigate the effect of material properties, such as shear viscosity (molecular weight), and processing conditions on polypropylene film formation and thermal/mechanical properties. We measure the width, velocity and temperature profiles as the film forms between the die and the chill roll. The polymer viscosity and the die temperature affect the film geometry and the temperature profiles in the air gap. The magnitude of the machine direction velocity component depends on both the machine and transverse direction position in the film. After the take-up, film samples are stretched in a controlled fashion, in which the strain rate and uniaxial stretch can be systematically varied. The effect of this processing history on film orientation and mechanical properties is reported. Finally, some modeling results are compared to experimental data.