Polypropylene plays a vital role in the medical industry—from non-absorbable surgical sutures and mesh implants to disposable medical textiles—benefiting from the material’s biocompatibility and mechanical strength. Specific characteristics such as compatibility with living tissue and resistance to bodily chemicals make polypropylene an ideal material for many medical applications. This article explores its key applications, technical features, advantages and disadvantages, and future directions.

Key Applications of Polypropylene in Medicine

Non-absorbable Surgical Sutures

One of the most widely known uses of polypropylene in the medical field is in manufacturing surgical sutures. These sutures are produced as monofilament threads, offering high flexibility and minimal tissue reaction, making them ideal for tissue approximation. As non-absorbable sutures, they are used in surgeries where long-term tissue support is necessary. The smooth surface of polypropylene monofilament allows for low-friction passage through tissue, minimizing trauma. Many sutures used in operating rooms are based on polypropylene.

Surgical Meshes and Implants

Surgical meshes, particularly those used in hernia repair, are predominantly woven from polypropylene. These non-absorbable meshes provide durable support for weakened tissue. Due to its high biocompatibility and low inflammatory response, polypropylene has long been the material of choice for hernia meshes and soft-tissue prosthetics. In addition to hernia repair, polypropylene meshes are also used in pelvic organ prolapse treatments. These meshes combine structural strength with flexibility to adapt to body movement.

Medical Bandages and Dressings

Polypropylene fibers are commonly used in the production of various medical dressings and bandages. Many sterile gauzes and advanced dressings are made of non-woven polypropylene layers that offer mechanical protection and are hypoallergenic and sterile. These layers help retain optimal moisture while preventing microbial intrusion. Polypropylene threads are also used in elastic bandages, often combined with other fibers for stretch and resilience.

Disposable Hygiene Textiles

A large portion of single-use medical products is made from polypropylene. Examples include surgical masks and their filters, surgical gowns and caps, shoe covers, and hygiene underpads—all often made from non-woven polypropylene fabrics. These textiles are cost-effective, scalable, and suitable for single-use applications. The COVID-19 pandemic highlighted the importance of such materials, as polypropylene-based masks and gowns were crucial in protecting healthcare workers.

Technical Features of Polypropylene in Medical Applications

High Biocompatibility

Polypropylene does not provoke significant immune responses when in contact with living tissue. It causes minimal inflammatory reactions and is generally well-tolerated, which is essential for wound healing and implant acceptance.

Tensile Strength and Long-Term Durability

Polypropylene sutures offer the strength needed to hold tissues together over extended periods. Unlike absorbable sutures, it does not degrade over time, making it suitable for permanent applications such as heart valve repairs or mesh implants.

Flexibility and Knot Security

Despite being a monofilament, polypropylene sutures are flexible enough for knotting. While they may be slightly slipperier than braided sutures, they hold knots securely with proper technique. In mesh applications, flexibility allows the mesh to conform to anatomical shapes without causing discomfort.

Chemical and Enzymatic Resistance

The internal body environment is rich in enzymes and fluids that can degrade some materials. Polypropylene resists these factors, avoiding hydrolysis and chemical corrosion, allowing it to remain stable for years inside the body.

Sterilizability

Medical devices must be sterilized prior to use. Polypropylene can be sterilized using various methods, including steam autoclaving (~121°C), ethylene oxide gas, or gamma radiation, with minimal impact on mechanical properties.

Lightweight and Radiolucent

Polypropylene has low density and does not interfere with radiological imaging (X-ray, MRI). This makes it ideal for internal implants like surgical meshes that need to remain invisible in diagnostic scans.

Advantages and Disadvantages of Using Polypropylene in Medicine

Advantages of Polypropylene in the Medical Industry

• Reduced Risk of Infection and Inflammation: Due to its inert nature, polypropylene causes fewer post-surgical complications compared to some other materials.
• Affordable and Widely Available: It is less expensive than many specialized medical-grade polymers and is readily available, even from domestic manufacturers, reducing dependency on imports.
• Multipurpose Utility: A single polypropylene base can be used to produce various medical items (sutures, masks, gowns), offering logistical and production efficiency.
• Tensile Strength Retention: Polypropylene performs well under continuous tension, making it suitable for orthopedic aids and high-stress applications. 

Disadvantages of Polypropylene in the Medical Industry

• Removal Requirement for External Sutures: Since it is non-absorbable, external sutures made of polypropylene must be manually removed, requiring follow-up care.
• Sensation of Foreign Body: Although biocompatible, polypropylene implants (especially large meshes) may cause discomfort or a feeling of tightness in some patients.
• Risk of Infection if Contaminated: While not a bacterial growth medium itself, contaminated polypropylene can host bacterial biofilms, leading to chronic infections.
• Less Flexibility than Braided Sutures: Being monofilament, polypropylene is stiffer than some braided alternatives and requires precision in knotting.
• Long-term Gamma Sterilization Limitations: Extended exposure to gamma radiation or prolonged storage may cause brittleness, which is why expiration dates are set for surgical polypropylene threads. 

The Future of Polypropylene in the Medical Industry

• Advancements in Smart Sutures and Enhanced Meshes: Research is ongoing to develop antibacterial-coated polypropylene sutures (e.g., silver or chlorhexidine) and 3D-structured meshes for better tissue integration.
• Expansion of Local Production for Medical Textiles: The COVID-19 pandemic emphasized the need for self-sufficiency. Many countries, including Iran, are increasing domestic production of spunbond and meltblown polypropylene fabrics.

• Development of Biodegradable Alternatives: Although polypropylene is non-absorbable, in some cases where absorption is desirable (e.g., subcutaneous sutures), research is exploring hybrid materials combining the durability of polypropylene with biodegradable coatings.
• Advanced Equipment Applications: Polypropylene nanofibers could be used in innovative medical equipment such as blood filtration systems or scaffolds in tissue engineering, where its mechanical properties provide structural support. 

Polypropylene remains a trusted, cost-effective, and high-performance material in the medical field. From surgical suites to patient wards, its presence is evident in a wide range of tools and textiles. Its unique combination of biocompatibility and mechanical durability has made it the standard for internal sutures and implants, while its versatility ensures continued relevance in disposable medical products. With ongoing innovation, polypropylene is set to remain a vital connector between materials science and modern medicine.