Acrylonitrile-butadiene-styrene (ABS) based composites with a high content of tungsten and bismuth oxide were developed using an innovative process to obtain lead-free x-ray shielding materials. ABS was chosen for its good mechanical properties and its widespread availability as a recycled material. The composites underwent flexural tests, Shore D hardness tests, thermogravimetric and morphological analysis, and their x-ray attenuation properties were determined through numerical simulations and experimental measurements. Despite their high filler content (up to 75 wt%), the composites showed good filler dispersion within the polymeric matrix and maintained their mechanical properties. Across the investigated energy range (50–150 kV), the lead equivalence for x-ray shielding was achieved with composite plates containing 75 wt% of tungsten and bismuth oxide, at thickness values corresponding to a weight increase of only 29% and 36%, respectively, in comparison to lead. These findings pave the way for a new generation of lead-free x-ray shielding materials. Moreover, their mechanical properties, including flexibility for potential application in wearable personal protective equipment, can be tailored by adjusting the filler content. Highlights: High filler content lead-free ABS composites with WO3 and Bi2O3 were developed. They show good polymer/filler interfacial adhesion and flexural properties. Numerical simulations of their x-ray shielding properties were performed. Experimental tests with polychromatic sources confirmed good x-ray attenuation. Results pave the way for the development of new lead-free x-ray shielding systems. © 2023 The Authors. Polymer Composites published by Wiley Periodicals LLC on behalf of Society of Plastics Engineers.

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