A two-level full factorial experimental design with three variables, formaldehyde-to-phenol (F/P) molar ratio, hydroxyl-to-phenol (OH/P) molar ratio, and condensation viscosity was implemented to determine the effect of the variables on the structure of phenol-formaldehyde resol resins for paper overlay impregnation. Ten resins were prepared with F/P molar ratios between 1.9 and 2.3, OH/P molar ratios between 0.09 and 0.13, and condensation viscosities between 60 and 180 mPa s. The effect of these three independent variables on the chemical structure was analyzed by C-13-NMR spectroscopy, on the molecular weight distribution by gel permeation chromatography, and on the reactivity by differential scanning calorimetry. (C) 2004 Wiley Periodicals, Inc.