AbstractThe effects of pressure ranging from 0.1 to 6.21 MPa (0–900 psig) on the curing of unsaturated polyester resins at 110°c were investigated by an approach of integrated reaction kinetics‐rheology‐morphology measurements using a pressure differential scanning calorimeter (DSC), an infrared spectrophotometer (IR), a Haake rheometer, and by using scanning electron microscopy (SEM). Increasing pressure was found to delay the gel effect, and a previously unknown plateau of kinetic‐controlled region in the initial portion of the DSC rate profile was observed. The plateau region was mainly attributed to the crosslinking of C  C double bonds inside the microgel particles, as revealed by the conversions of styrene and polyester C  C bonds measured by IR, gel conversion data and SEM micrographs. The mechanisms of reaction kinetics both at atmospheric pressure and under pressures have also been elucidated by the progress of buildup of microge