This is an unedited manuscript accepted for publication and provided as an Article in Press for early access at the author’s request. The article will undergo copyediting, typesetting, and galley proof review before final publication. Please be aware that errors may be identified during production that could affect the content. All legal disclaimers of the journal apply.
Sachin Gugwad,
Shashikiran N. D.,
Namrata Gaonkar,
- Professor, Department of Pediatric and Preventive Dentistry, School of Dental Sciences, Krishna Vishwa Vidyapeeth “Deemed to be University”, Taluka-Karad, Dist-Satara, Maharashtra, India
- Professor, Department of Pediatric and Preventive Dentistry, School of Dental Sciences, Krishna Vishwa Vidyapeeth “Deemed to be University”, Taluka-Karad, Dist-Satara, Maharashtra, India
- Associate Professor, Department of Pediatric and Preventive Dentistry, School of Dental Sciences, Krishna Vishwa Vidyapeeth “Deemed to be University”, Taluka-Karad, Dist-Satara, Maharashtra, India
Abstract
Radiopaque polymer composites are increasingly important for improving the visualization of interventional medical devices under X-ray and fluoroscopic imaging while maintaining the flexibility, mechanical performance, and processability required for minimally invasive applications. This narrative review summarizes recent developments in radiopaque polymer composites, with emphasis on radiopaque filler selection, polymer–filler interactions, processing strategies, structure–property relationships, biocompatibility, and device applications. A focused literature search was conducted using PubMed, Scopus, Web of Science, IEEE Xplore, ScienceDirect, and Google Scholar, primarily considering publications from 2015 to 2025 together with selected earlier landmark studies. A total of 27 relevant publications were identified and critically reviewed. The review discusses commonly used radiopaque fillers, including barium sulfate, bismuth-based fillers, tungsten, tantalum, iodinated organic materials, and emerging inorganic and hybrid systems, along with their integration into polymer matrices such as thermoplastic polyurethane, polyether block amide, silicone, polyvinylidene fluoride, and biodegradable polymers. The reviewed literature indicates that radiopacity must be balanced with flexibility, mechanical integrity, filler dispersion, processability, interfacial adhesion, and long-term biocompatibility. Because the reported studies differ substantially in polymer matrices, filler loading, particle characteristics, specimen dimensions, imaging conditions, and testing protocols, directly comparable quantitative data were not consistently available; therefore, the present review provides a qualitative comparative synthesis rather than a formal quantitative analysis. Applications in vascular, neurovascular, gastrointestinal, urological, orthopedic, and drug-delivery devices are discussed. Emerging approaches, including nanocomposites, hybrid fillers, surface modification, and additive manufacturing, offer opportunities for application-specific and multifunctional radiopaque devices. Future research should focus on optimizing radiopacity while preserving mechanical performance, biocompatibility, processing characteristics, and imaging compatibility.
Keywords: Radiopacity; Polymer composites; Interventional devices; X-ray visibility; Fluoroscopy; Nanocomposites; Heavy-metal fillers; Barium sulfate; Bismuth oxide; Tungsten; Device visualization; Biomaterials; Minimally invasive procedures.
References
- Wang Q, Yu X, Chen X, Gao J, Shi D, Shen Y, et al. A facile composite strategy to prepare a biodegradable polymer based radiopaque raw material for “visualizable” biomedical implants. ACS Appl Mater Interfaces. 2022;14(21):24197-24212. doi:10.1021/acsami.2c05184.
- Shahzad K, Kausar A, Manzoor S, Rakha SA, Uzair A, Sajid M, et al. Views on radiation shielding efficiency of polymeric composites/nanocomposites and multi-layered materials: current state and advancements. Radiation. 2022;3(1):1-20.
- Jeong YJ, Choi B, Kim S, Jo J, Shanmugasundaram A, Kang S, et al. Fully bioresorbable, all-polymer-based, 3D-printed scaffolds with prolonged radiopacity and enhanced durability. Chem Eng J. 2024;494:152851. doi:10.1016/j.cej.2024.152851.
- Sneha KR, Sailaja GS. Intrinsically radiopaque biomaterial assortments: a short review on the physical principles, X-ray imageability, and state-of-the-art developments. J Mater Chem B. 2021;9(41):8569-8593. doi:10.1039/D1TB01513C.
- Kumar R, Pattanayak I, Dash PA, Mohanty S. Bioceramics: a review on design concepts toward tailor-made (multi)-functional materials for tissue engineering applications. J Mater Sci. 2023;58(8):3460-3484. doi:10.1007/s10853-023-08226-8.
- Gunaseelan N, Saha P, Maher N, Pan D. Nanoparticles with “K-edge” metals bring “color” in multiscale spectral photon counting X-ray imaging. ACS Nano. 2024;18(51):34464-34491. doi:10.1021/acsnano.4c11724.
- Shahbazi MA, Faghfouri L, Ferreira MPA, Figueiredo P, Maleki H, Sefat F, et al. The versatile biomedical applications of bismuth-based nanoparticles and composites: therapeutic, diagnostic, biosensing, and regenerative properties. Chem Soc Rev. 2020;49(4):1253-1321. doi:10.1039/C9CS00283A.
- Hasan SM, Harmon G, Zhou F, Raymond JE, Gustafson TP, Wilson TS, et al. Tungsten-loaded SMP foam nanocomposites with inherent radiopacity and tunable thermo-mechanical properties. Polym Adv Technol. 2016;27(2):195-203. doi:10.1002/pat.3621.
- Koshevaya E, Krivoshapkina E, Krivoshapkin P. Tantalum oxide nanoparticles as an advanced platform for cancer diagnostics: a review and perspective. J Mater Chem B. 2021;9(25):5008-5024. doi:10.1039/D1TB00570G.
- Choi G, Choi B, Darmawan BA, Jeong S, Jo J, Choi E, et al. Radiopaque, self-immolative poly(benzyl ether) as a functional X-ray contrast agent: synthesis, prolonged visibility, and controlled degradation. Biomacromolecules. 2024;25(5):2740-2748. doi:10.1021/acs.biomac.3c01392.
- Montazerian M, Gonçalves GVS, Barreto MEV, Lima EPN, Cerqueira GRC, Sousa JA, et al. Radiopaque crystalline, non-crystalline and nanostructured bioceramics. Materials (Basel). 2022;15(21):7477. doi:10.3390/ma15217477.
- Drożdż K, Gołda-Cępa M, Brzychczy-Włoch M. Polyurethanes as biomaterials in medicine: advanced applications, infection challenges, and innovative surface modification methods. Adv Microbiol. 2024;63(4):223-238. doi:10.2478/am-2024-0018.
- Nugent A, Molloy J, Kelly M, Colbert DM. Co-optimization of mechanical properties and radiopacity through radiopaque filler incorporation for medical tubing applications. Polymers (Basel). 2024;16(22):3220. doi:10.3390/polym16223220.
- Sahu BB, Moharana S, Behera PK. Elastomeric-based composite materials for engineering applications. In: Sahu BB, Moharana S, Behera PK, editors. Polymer Composites. Singapore: Springer Nature Singapore; 2024. p.329-355. doi:10.1007/978-981-97-2075-0_11.
- Griffith DM, Li H, Werrett MV, Andrews PC, Sun H. Medicinal chemistry and biomedical applications of bismuth-based compounds and nanoparticles. Chem Soc Rev. 2021;50(21):12037-12069. doi:10.1039/D0CS00031K.
- Ding Y, Fu R, Collins CP, Yoda SF, Sun C, Ameer GA. 3D-printed radiopaque bioresorbable stents to improve device visualization. Adv Healthc Mater. 2022;11(23):e2201955. doi:10.1002/adhm.202201955.
- Vahabli E, Mann J, Heidari BS, Lawrence-Brown M, Norman P, Jansen S, et al. The technological advancement to engineer next-generation stent-grafts: design, material, and fabrication techniques. Adv Healthc Mater. 2022;11(13):e2200271. doi:10.1002/adhm.202200271.
- Losetty V, Lakkaboyana SK, Chappidi HY, Venkateswarlu K, Trilaksana H, Koduru JR, et al. Transformative applications of polymer-based metal oxide nanocomposites in medicine, industry, and environmental remediation: a review. J Inorg Organomet Polym Mater. 2026;36(1):64-96. doi:10.1007/s10904-025-03707-6.
- Etxeberria L, Badiola JH, Astigarraga M, Garitaonandia F, Zaldua AM. Comparison between injection molding (IM) and injection-compression molding (ICM) for mass manufacturing of thermoplastic microfluidic devices. Macromol Mater Eng. 2023;309(1):2300231. doi:10.1002/mame.202300231.
- Shannon A, O’Sullivan KJ, Clifford S, O’Sullivan L. Assessment and selection of filler compounds for radiopaque PolyJet multi-material 3D printing for use in clinical settings. Proc Inst Mech Eng H. 2022;236(5):740-747. doi:10.1177/09544119221084819.
- Mendes M, et al. Radiopacity enhancements in polymeric implant biomaterials: a comprehensive literature review. ACS Biomater Sci Eng. 2024;10(5):2674-2695. doi:10.1021/acsbiomaterials.3c01667.
- Dong M, Sun Y, Dunstan DJ, Young RJ, Papageorgiou DG. Mechanical reinforcement from two-dimensional nanofillers: model, bulk and hybrid polymer nanocomposites. Nanoscale. 2024;16(28):13247-13299. doi:10.1039/D4NR01356E.
- Olivieri A, et al. High filler content acrylonitrile-butadiene-styrene composites containing tungsten and bismuth oxides for effective lead-free X-ray radiation shielding. Polym Compos. 2024. doi:10.1002/pc.27906.
- Pawelec KM, Tu E, Chakravarty S, Hix JML, Buchanan L, Kenney L, et al. Incorporating tantalum oxide nanoparticles into implantable polymeric biomedical devices for radiological monitoring. Adv Healthc Mater. 2023;12(18):e2203167. doi:10.1002/adhm.202203167.
- Chang CT, Chen HT, Girsang SP, Chen YM, Wan D, Shen SH, et al. 3D-printed radiopaque polymer composites for the in situ monitoring of biodegradable medical implants. Acta Biomater. 2020;110:141-151. doi:10.1016/j.actbio.2020.04.020.

Journal of Polymer & Composites
| Volume | 14 | |
| 04 | ||
| Received | 20/07/2026 | |
| Accepted | 31/08/2026 | |
| Published | 09/09/2026 | |
| Publication Time | 51 Days |