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Phillipsburg was incorporated as a town by an Act of the New Jersey Legislature on March 8, 1861, from portions of Phillipsburg Township (now Lopatcong Township).
The town is located in western New Jersey, on the border of Pennsylvania, and is considered the eastern border of the region's Lehigh Valley.
According to the United States Census Bureau, the town has a total area of 3.3 square miles (8.7 km
Pohatcong Mountain is a ridge, approximately 6 mi (10 km) long, in the Appalachian Mountains that extends from Phillipsburg northeast approximately to Washington.