The role of fiber morphology in a thermal point-bonding operation was investigated. Polypropylene fibers were spun to produce fibers with a wide range of structure, keeping the diameter same. The fibers were characterized for their structure and properties before and after bonding by differential scanning calorimeter (DSC), thermo-mechanical analysis (TMA), birefringence measurement and tensile testing. The results show that the fiber samples with different morphology vary in their bonding behavior, which in rum determine the fabric properties. Significant changes were observed in fiber structure during thermal bonding. The extent of change taking place during the process was dependent on the initial morphology of the fibers.