A series of water dispersion polyurethanes dispersions (PUDs) were prepared by polyaddition reaction using isophorone diisocyanate (IPDI), toluene diisocyanate (TDI), poly(oxytetramethylene) glycol (PTMG), dimethylol propionic acid (DMPA), and triol (trade name FA-703). Various formulations were designed to investigate the effects of process variables such as TDI and FA-703 on the physico-mechanical properties of PUD. IR spectroscopy was used to check the end of polymerization reaction and characterization of polymer. Evolution of the particle size distribution, contact angle, T(g), molecular weight, viscosity, and mechanical properties of the emulsion-cast films were significantly affected by variable content of TDI and FA-703. Average particle size of the prepared polyurethane emulsions and contact angle decrease with increase of content of FA-703 and TDI. Molecular weight, Tg, tensile strength, tear strength, hardness, viscosity and elongation at break increase with increase of content of FA-703 and TDI. The increase of molecular weight, tensile strength, tear strength and elongation at break properties are interpreted in terms of increasing hard segments, chain flexibility, and phase separation in high content of FA-703 and TDI-based polyurethane. (C) 2011 Wiley Periodicals, Inc. J Appl Polym Sci 121: 8-13, 2011