The unique advantage of polymer bead foams (e.g. expanded Polypropylene, EPP) is the combination of complex geometrical structure with extreme low density in the range of 20-200 kg/m3, excellent thermal insulation, and good specific mechanical properties. Therefore, this class of materials is used in many lightweight applications, e.g. automotive, construction, packaging, sports etc. However, there are some challenges regarding the high energy and steam consumption during the conventional processing via steam-chest molding. Additionally, in-situ functionalization of bead foams on the one hand by face sheets to produce sandwich composite structures and on the other hand by coating the beads to tailor the foam properties, still has limitations and requires a more flexible method. To increase the process efficiency and the application scope of bead foams, novel processing technologies are in a great demand. This study applies microwave molding of polymer bead foams. We discuss the influence of (1) microwave molding conditions on the fusion quality in EPP (2) incorporated bead coating on the extend of fusion (3) adding face sheets on the fusion quality within the bead foam core and between core and the face sheets. Results demonstrate the suitability of microwave processing for efficient and homogeneous welding of EPP, EPP coated with flame retardant additives, and sandwich structures with EPP core. The internal heating with microwave energy allows for more structural/functional flexibility and for the reduction of processing time without externally supplied steam. At the same time, products show similar or even better properties compared to the conventionally produced bead foams.