An Overview of 3D Printing Technologies for Food Fabrication

Recent research and applications in lipid-based food and lipid-incorporated bioink for 3D printing

Three-dimensional (3D) printing, as an emerging digital production technology, has recently been receiving increasing attention in food processing. It is important to understand the effect of key ingredients of food materials on the printing, which makes it possible to achieve a wider range of structures using few nozzles and to provide tailored nutrition and personalization. This comprehensive review delves into the latest research on 3D-printed lipid-based foods, encompassing a variety of products such as chocolate, processed cheese, as well as meat. It also explores the development and application of food bioinks that incorporate lipids as a pivotal component, including those based on starch, protein, oleogels, bigels, and emulsions, as well as emulsion gels. Moreover, this review identifies the current challenges and presents an outlook on future research directions in the field of 3D food printing, especially the research and application of lipids in food 3D printing.

State of the art, challenges, and future prospects for the multi-material 3D printing of plant-based meat

The emergence of innovative plant-based meat analogs, replicating the flavor, texture, and appearance of animal meat cuts, is deemed crucial for sustainably feeding a growing population while mitigating the environmental impact associated with livestock farming. Multi-material 3D food printing (MM3DFP) has been proposed as a potentially disruptive technology for manufacturing the next generation of plant-based meat analogs. This article provides a comprehensive review of the state of the art, addressing various aspects of 3D printing in the realm of plant-based meat. The disruptive potential of printed meat analogs is discussed with particular emphasis on protein-rich, lipid-rich, and blood-mimicking food inks. The printing parameters, printing requirements, and rheological properties at the different printing stages are addressed in detail. As food rheology plays a key role in the printing process, an appraisal of this subject is performed. Post-printing treatments are assessed based on the extent of improvement in the quality of 3D-printed plant-based meat analogs. The meat-mimicking potential is revealed through sensory attributes, such as texture and flavor. Furthermore, there has been limited research into food safety and nutrition. Economically, the 3D printing of plant-based meat analogs demonstrates significant market potential, contingent upon innovative decision-making strategies and supportive policies to enhance consumer acceptance. This review examines the current limitations of this technology and highlights opportunities for future developments.

Improvement of jelly 3D printing using ultrasound treatment and calcium chloride

This study investigated the effects of ultrasound treatment or calcium chloride (CaCl2) addition on the physical properties of jelly formulations. Elastic modulus (G'), loss modulus (G"), tan δ, shear modulus, yield stress (τ0), phase angle (δ), and gel strength were the parameters selected to describe the requirements of jelly printing, such as fidelity, shape retention, and extrudability. Ultrasound treatment of the jelly formulation without pectin increased the G' and shear moduli values, while decreasing the δ and gel strength. The addition of CaCl2 to the jelly formulation with pectin increased the G', G", shear modulus, τ0, and gel strength but lowered the tan δ and δ values. Both ultrasound treatment and CaCl2 addition improved the jelly printing requirements and demonstrated the potential to control the physical properties of jelly formulations for 3D printing using fused deposition modeling.

Recent advances in implantable sensors and electronics using printable materials for advanced healthcare

This review article focuses on the recent printing technological progress in healthcare, underscoring the significant potential of implantable devices across diverse applications. Printing technologies have widespread use in developing health monitoring devices, diagnostic systems, and surgical devices. Recent years have witnessed remarkable progress in fabricating low-profile implantable devices, driven by advancements in printing technologies and nanomaterials. The importance of implantable biosensors and bioelectronics is highlighted, specifically exploring printing tools using bio-printable inks for practical applications, including a detailed examination of fabrication processes and essential parameters. This review also justifies the need for mechanical and electrical compatibility between bioelectronics and biological tissues. In addition to technological aspects, this article delves into the importance of appropriate packaging methods to enhance implantable devices' performance, compatibility, and longevity, which are made possible by integrating cutting-edge printing technology. Collectively, we aim to shed light on the holistic landscape of implantable biosensors and bioelectronics, showcasing their evolving role in advancing healthcare through innovative printing technologies.

Towards the development of foods 3D printer: Trends and technologies for foods printing

3D printing of food materials is among the innovations that could revolutionize people's food choices and consumption. Food innovation and production have advanced considerably in recent years and its market has shown rapid annual expansion. Printing food technologies are considered as a potential solution for producing customized foods such as military food, and astronaut food. The printable food ink material still lacks standardization and superior extrusion process compared to other 3D printing industries. This review paper aimed to provide a comprehensive review of the current foods 3D printing and the latest technology in certain terms and with its concrete applications. In particular, the following issues are discussed: the printing techniques, exudations classes, business prospects, technologies, printing parameters, food materials, safety, and challenges and limitations of food 3D printing along with possible improvement recommendations. Significant printing parameters have been summarized and the safety of the food printing has been evaluated. Moreover, this article also contains a detailed, tabular evaluation of technical approaches employed across researched based and commercially available systems. One of the major limitations that need to be resolved was standardization of food printing safety.

Protein and protein-polysaccharide composites-based 3D printing: The properties, roles and opportunities in future functional foods

The food industry is undergoing a significant transformation with the advancement of 3D technology. Researchers in the field are increasingly interested in using protein and protein-polysaccharide composite materials for 3D printing applications. However, maintaining nutritional and sensory properties while guaranteeing printability of these materials is challenging. This review examines the commonly used protein and composite materials in food 3D printing and their roles in printing inks. This review also outlines the essential properties required for 3D printing, including extrudability, appropriate viscoelasticity, thixotropic properties, and gelation properties. Furthermore, it explores the wide range of potential applications for 3D printing technology in novel functional foods such as space food, dysphagia food, kid's food, meat analogue, and other specialized food products.

The present state and future outlook of pectin-based nanoparticles in the stabilization of Pickering emulsions

The stabilization of Pickering emulsions using micro/nanoparticles has gained significant attention due to their wide range of potential applications in industries such as cosmetics, food, catalysis, tissue engineering, and drug delivery. There is a growing demand for the development of environmentally friendly micro/nanoparticles to create stable Pickering emulsions. Naturally occurring polysaccharides like pectin offer promising options as they can assemble at oil/water interfaces. This polysaccharide is considered a green candidate because of its biodegradability and renewable nature. The physicochemical properties of micro/nanoparticles, influenced by fabrication methods and post-modification techniques, greatly impact the characteristics and applications of the resulting Pickering emulsions. This review focuses on recent advancements in Pickering emulsions stabilized by pectin-based micro/nanoparticles, as well as the application of functional materials in delivery systems, bio-based films and 3D printing using these emulsions as templates. The effects of micro/nanoparticle properties on the characteristics of Pickering emulsions and their applications are discussed. Additionally, the obstacles that currently hinder the practical implementation of pectin-based micro/nanoparticles and Pickering emulsions, along with future prospects for their development, are addressed.

Tulane Virus Persistence and Microbial Stability in 3D Food Ink under Various Storage Conditions: A Pre- and Post-Printing Analysis

3D food printers facilitate novel customization of the physicochemical properties of food. This study aimed to investigate the impact of storage conditions on the inactivation of the human norovirus surrogate, Tulane virus (TuV), within 3D printed foods. TuV-inoculated protein cookie food ink (∽ 4 log PFU/g) was distributed into 18 3D food printer capsules (50 g each); half immediately underwent extrusion. Storage of the capsules and printed food products at 20 °C (0, 6, 12, and 24 h), 4 °C (0, 1, 3, and 5d), and - 18 °C (0, 1, 3, and 5d) was completed before analysis for TuV via plaque assays in addition to aerobic plate count, yeast and mold counts, and pH and water activity (aw) measurements. A significant 3-way interaction effect was observed between time, temperature, and storage method (capsule/print) (p = 0.006). Significant findings include: (1) A greater reduction in virions was observed in capsules after 24 h at 20 °C and (2) a substantial reduction in virions at 4 °C from day 0 to day 1 was observed, independent of storage method. Microbial indicators remained steady across temperatures, with storage temperature significantly impacting pH and aw. A significant two-way interaction effect (p = 0.006) was found between microorganism type (yeast/aerobic counts) and temperature. This research seeks to provide insights for the food industry and regulatory bodies in crafting guidelines for the safe storage and handling of 3D printed foods and inks.

The complexities of decision-making in food waste valorization: A critical review

The efficient utilization of food waste (FW) resources through Food Waste Valorization (FWV) has received increasing attention in recent years. Various decision-making studies have been undertaken to facilitate FWV implementation, such as the studies on decision-making framework and FWV technology assessment. Food waste hierarchy is a widely discussed framework in FW management, but it was found too simplified and does not always contribute positively to environmental sustainability. Moreover, decision-making studies in FWV often focus on specific aspects of the food system and employ distinctive decision-making approaches, making it difficult to compare the results from different studies. Therefore, our literature review is conducted to provide a comprehensive understanding of FWV decision-making. This study identifies what decisions are needed, and three levels of decisions are revealed: system-level, FW stream-level, and FWV option-level. The assessment approaches and criteria used to support decision-making in FWV are also collected and analyzed. Building upon these findings, an hourglass model is synthesized to provide a holistic illustration of decision-making in FWV. This study untangles the complexities of FWV decision-making and sheds light on the limitations of current studies. We anticipate this study will make more people realize that FWV is a multidisciplinary issue and requires the collective participation of researchers, practitioners, policymakers, and consumers. Such collective engagement is essential to effectively address practical challenges and propel the transition of the current food system toward a more resource-efficient paradigm.

Investigation of the structure, rheology and 3D printing characteristics of corn starch regulated by glycyrrhizic acid

This study aimed to construct a novel corn starch-glycyrrhizic acid (CS-GA) ink and systematically investigate the effects of GA on the water distribution, microstructure, rheology and 3D printing properties of CS hydrogels. The results showed that the CS chains could form strong hydrogen bonds with GA molecules, inhibit the formation of short-range ordered structure of CS and reduce the content of B-type starch. The low-field nuclear magnetic results showed that the introduction of GA could increase bound water content in CS-GA hydrogels. With the increase of GA content, the CS-GA hydrogel changed from CS-dominated to a GA-dominated gel network system. Rheological results showed that all samples exhibited typical shear thinning behavior. High GA concentration was beneficial to increasing the self-supporting properties and thixotropic recovery of CS-GA hydrogels. Compared with the pure CS hydrogel, the 3D printing characteristics of CS-GA hydrogels were significantly enhanced due to the increased bound water content and the enhancement of rheological properties. At 40 % GA content, CS-GA hydrogel showed the highest printing accuracy of 96.4 % ± 0.30 %. The printed product could perfectly replicate the preset model. Therefore, this study provided a theoretical basis for regulating starch's rheology and 3D printing characteristics and developing novel food-grade 3D printing inks.

3D Printing of Materials and Printing Parameters with Animal Resources: A Review

3D printing technology enables the production of creative and personalized food products that meet consumer needs, such as an attractive visual appearance, fortification of specific nutrients, and modified textures. To popularize and diversify 3D-printed foods, an evaluation of the printing feasibility of various food pastes, including materials that cannot be printed natively, is necessary. Most animal resources, such as meat, milk, and eggs, are not inherently printable; therefore, the rheological properties governing printability should be improved through pre-/post-processing or adding appropriate additives. This review provides the latest progress in extrusion-based 3D printing of animal resource-based inks. In addition, this review discusses the effects of ink composition, printing conditions, and post-processing on the printing performance and characteristics of printed constructs. Further research is required to enhance the sensory quality and nutritional and textural properties of animal resource-based printed foods.

A review of high internal phase Pickering emulsions: Stabilization, rheology, and 3D printing application

High internal phase Pickering emulsion (HIPPE) is renowned for its exceptionally high-volume fraction of internal phase, leading to flocculated yet deformed emulsion droplets and unique rheological behaviors such as shear-thinning property, viscoelasticity, and thixotropic recovery. Alongside the inherent features of regular emulsion systems, such as large interfacial area and well-mixture of two immiscible liquids, the HIPPEs have been emerging as building blocks to construct three-dimensional (3D) scaffolds with customized structures and programmable functions using an extrusion-based 3D printing technique, making 3D-printed HIPPE-based scaffolds attract widespread interest from various fields such as food science, biotechnology, environmental science, and energy transfer. Herein, the recent advances in preparing suitable HIPPEs as 3D printing inks for various applied fields are reviewed. This work begins with the stabilization mechanism of HIPPEs, followed by introducing the origin of their distinctive rheological behaviors and strategies to adjust the rheological behaviors to prepare more eligible HIPPEs as printing inks. Then, the compatibility between extrusion-based 3D printing and HIPPEs as building blocks was discussed, followed by a summary of the potential applications using 3D-printed HIPPE-based scaffolds. Finally, limitations and future perspectives on preparing HIPPE-based materials using extrusion-based 3D printing were presented.

Reducing meat consumption in Central Asia through 3D printing of plant-based protein-enhanced alternatives-a mini review

3D food printing (3DFP) is emerging as a vital innovation in the food industry's pursuit of sustainability. 3DFP has evolved to significantly impact food production, offering the capability to create customized, nutritionally balanced foods. Central Asia has a higher than global average level of meat consumption per capita, which might be influenced by its historical and cultural background of nomadism. This dietary trend might potentially result in negative impacts on both the environment and human health outcomes, as it leads to increased greenhouse gas emissions and increased risk of chronic diseases. Reducing meat consumption holds the potential to address these sustainability and health issues. A possible strategy to reduce meat consumption and promote plant-based foods is 3D Food Printing (3DFP), which can rely on plant-protein sources from the region to create appealing and tasty alternatives for these populations. This review summarizes recent studies on plant protein-rich materials for 3DFP as a substitute to meet the growing global demand for meat as well as the 3DFP printing parameters associated with the different plant-based proteins currently used (e.g., lentils, soybeans, peas, and buckwheat). The findings revealed that buckwheat, a dietary staple in Central Asia, can be a promising choice for 3DFP technology due to its widespread consumption in the region, gluten-free nature, and highly nutritious profile.

Food Processing and Nutrition Strategies for Improving the Health of Elderly People with Dysphagia: A Review of Recent Developments

Dysphagia, or swallowing difficulty, is a common morbidity affecting 10% to 33% of the elderly population. Individuals with dysphagia can experience appetite, reduction, weight loss, and malnutrition as well as even aspiration, dehydration, and long-term healthcare issues. However, current therapies to treat dysphagia can routinely cause discomfort and pain to patients. To prevent these risks, a non-traumatic and effective treatment of diet modification for safe chewing and swallowing is urgently needed for the elderly. This review mainly summarizes the chewing and swallowing changes in the elderly, as well as important risk factors and potential consequences of dysphagia. In addition, three texture-modified food processing strategies to prepare special foods for the aged, as well as the current statuses and future trends of such foods, are discussed. Nonthermal food technologies, gelation, and 3D printing techniques have been developed to prepare soft, moist, and palatable texture-modified foods for chewing and swallowing safety in elderly individuals. In addition, flavor enhancement and nutrition enrichment are also considered to compensate for the loss of sensory experience and nutrients. Given the trend of population aging, multidisciplinary cooperation for dysphagia management should be a top priority.

Challenges and Prospects of Plant-Protein-Based 3D Printing

Three-dimensional (3D) printing is a rapidly developing additive manufacturing technique consisting of the deposition of materials layer-by-layer to produce physical 3D structures. The technique offers unique opportunities to design and produce new products that cater to consumer experience and nutritional requirements. In the past two decades, a wide range of materials, especially plant-protein-based materials, have been documented for the development of personalized food owing to their nutritional and environmental benefits. Despite these benefits, 3D printing with plant-protein-based materials present significant challenges because there is a lack of a comprehensive study that takes into account the most relevant aspects of the processes involved in producing plant-protein-based printable items. This review takes into account the multi-dimensional aspects of processes that lead to the formulation of successful printable products which includes an understanding of rheological characteristics of plant proteins and 3D-printing parameters, as well as elucidating the appropriate concentration and structural hierarchy that are required to maintain stability of the substrate after printing. This review also highlighted the significant and most recent research on 3D food printing with a wide range of plant proteins. This review also suggests a future research direction of 3D printing with plant proteins.

Three-dimensional food printing: its readiness for a food and nutrition insecure world

Three-dimensional (3D) food printing is a rapidly emerging technology offering unprecedented potential for customised food design and personalised nutrition. Here, we evaluate the technological advances in extrusion-based 3D food printing and its possibilities to promote healthy and sustainable eating. We consider the challenges in implementing the technology in real-world applications. We propose viable applications for 3D food printing in health care, health promotion and food waste upcycling. Finally, we outline future work on 3D food printing in food safety, acceptability and economics, ethics and regulations.

Three-Dimensional Printing of Foods: A Critical Review of the Present State in Healthcare Applications, and Potential Risks and Benefits

Three-dimensional printing is one of the most precise manufacturing technologies with a wide variety of applications. Three-dimensional food printing offers potential benefits for food production in terms of modifying texture, personalized nutrition, and adaptation to specific consumers' needs, among others. It could enable innovative and complex foods to be presented attractively, create uniquely textured foods tailored to patients with dysphagia, and support sustainability by reducing waste, utilizing by-products, and incorporating eco-friendly ingredients. Notable applications to date include, but are not limited to, printing novel shapes and complex geometries from candy, chocolate, or pasta, and bio-printed meats. The main challenges of 3D printing include nutritional quality and manufacturing issues. Currently, little research has explored the impact of 3D food printing on nutrient density, bioaccessibility/bioavailability, and the impact of matrix integrity loss on diet quality. The technology also faces challenges such as consumer acceptability, food safety and regulatory concerns. Possible adverse health effects due to overconsumption or the ultra-processed nature of 3D printed foods are major potential pitfalls. This review describes the state-of-the-art of 3D food printing technology from a nutritional perspective, highlighting potential applications and current limitations of this technology, and discusses the potential nutritional risks and benefits of 3D food printing.

Improvement of 3D white chocolate printing molding effect with oleogels

This study used oleogels to resolve unsolidified white chocolate in 3D printing. Because white chocolate cannot be shaped during 3D printing, the oleogel system is used to solve this problem. The printing parameters and accuracy in a 3D printing system were investigated by using different oleogels added to white chocolate as a material to enhance chocolate extrusion solidification, monoglycerides (MAG), sucrose fatty acid ester (SE) and hydroxypropyl methylcellulose (HPMC), and their effects on rheological characterization, bridging experiments, and optimal print parameters (material formulation, nozzle height, layer height and print speed) were compared. In the rheological analysis, the viscosity recovery was more than 80% for the HPMC group and less than 80% for the MAG and SE groups. In the bridging experiment, when MAG and SE were added at more than 2%, the white chocolate could be effectively extruded and solidified, and the bridging distance could be stretched to 10 mm. The suitable printing parameters are a nozzle height of 3 mm, a layer height of 3 mm, and a printing speed of 10 mm/s. This study provides a future solution to solve the problem of extruded unsolidified chocolate.

Mairá-Potato (Casimirella sp.): Botanical, Food, Pharmacological, and Phytochemical Aspects

Millions of people in the world live in food insecurity, so identifying a tuber with characteristics capable of meeting the demand for food and also identifying active compounds that can be used to minimize harm to human health is of great value. The aim was to carry out a review based on systematic review tools and the main objective was to seek information on botanical, food, pharmacological, and phytochemical aspects of Casimirella sp. and propose possible applications. This review showed papers that addressed botanical, food, pharmacological, and phytochemical aspects of the Mairá-potato and presented suggestions for using this tuber allied to the information described in the works found in the Google Academic, Scielo, Science Direct, Scopus, PubMed, and Web of Science databases. This review synthesized knowledge about the Mairá-potato that can contribute to the direction of further research on the suggested technological applications, both on the use of this tuber as a polymeric material and its use as biomaterial, encapsulation, bioactive use, and 3D printing, because this work collected information about this non-conventional food plant (PANC) that shows great potential for use in various areas of study.

Transfer rates of Salmonella Typhimurium, Listeria monocytogenes, and a human norovirus surrogate impacted by macronutrient composition of food inks in 3D food printing systems

3D food printers (3DFPs) allow for the customization of the physiochemical properties of foods in new ways. Transfer kinetics of foodborne pathogens between surfaces and food inks have not been evaluated in 3DFPs. This study aimed to determine if the macromolecular composition of food inks would impact the transfer rate of foodborne pathogens from the stainless steel food ink capsule to the 3D printed food. Salmonella Typhimurium, Listeria monocytogenes, and a human norovirus surrogate, Tulane virus (TuV), were inoculated onto the interior surface of stainless steel food ink capsules and dried for 30 min. Subsequently, 100 g of one of the following prepared food inks was extruded: (1) pure butter, (2) a powdered sugar solution, (3) a protein powder solution, and (4) a 1:1:1 ratio of all three macromolecules. Pathogen enumeration was completed for both the soiled capsules and the printed food products and resulting transfer rates were estimated using a generalized linear model with quasibinomial errors. A significant two-way interaction effect was found between microorganism type and food ink type (P = 0.0002). Tulane virus was typically transferred the most, and no significant differences between L. monocytogenes and S. Typhimurium were observed for any food matrix or across food matrices. Among food matrices, the complex mixture transferred fewer microorganisms in all instances, while butter, protein, and sugar were all statistically indistinguishable. This research seeks to further develop the field of 3DFP safety and to advance the understanding of the role of macromolecular composition in pathogen transfer kinetics, which have not previously been explored in pure matrices.

The Influence of Filament Orientation on Tensile Stiffness in 3D Printed Structures-Numerical and Experimental Studies

The present study provides a thorough analysis of the influence of filament orientation on the tensile stiffness of 3D-printed structures. This exploration employs a combination of numerical simulations and experimental trials, providing an extensive understanding of additive manufacturing, particularly 3D printing. This process involves layer-by-layer material deposition to produce three-dimensional objects. The examination specifically targets PLA-based 3D printed structures created using Fused Filament Fabrication (FFF) technology and subjects them to rigorous evaluations using a universal tensile testing machine. Additionally, this approach combines Representative Volume Element (RVE) and Classical Lamination Theory (CLT) techniques to extrapolate the mechanical properties of the test material. Although the initial methodology faces challenges in determining the shear modulus with precision, an in-depth investigation results in enhanced accuracy. Furthermore, this study introduces a parametric RVE numerical method, demonstrating its resilience in handling sensitivity to shear modulus. A comparative study of results derived from both the analytical methods and experimental trials involving five series of samples with varied layups reveals that the newly proposed numerical method shows a stronger correlation with the experimental outcomes, delivering a relative error margin of up to 8%.

Rheological and physicochemical properties of Spirulina platensis residues-based inks for extrusion 3D food printing

Novel food matrices (such as microalgae, plants, fungi, and microbial proteins) with high protein content and biological value, good amino acid profile, and functionality have been explored. Phycocyanin and active polysaccharides extracted from Spirulina platensis are used as food additives, treatment of colitis, as well as obesity prevention. However, most of the remaining Spirulina platensis residues are mainly used as fish feed at present. 3D food printing is one of the promising development techniques used in the food industry. The aim of this study was to develop a novel 3D printing material of Spirulina platensis residues with shear thinning characteristics, high viscosity and rapid recovery. The effects of moisture content and pretreatment method on the rheological properties of Spirulina platensis residues were clarified. Scanning electron microscopy was used to observe the microstructure and texture profile analysis was used to determine the texture characteristics of Spirulina platensis residues, rheology was used to determine the key 3D printing factors such as viscosity and modulus of Spirulina platensis residues. More importantly, the printing process could be realized under ambient conditions. The development of microalgae residue ink promoted the high-value and comprehensive utilization of microalgae, and also broadened the application of microalgae in the food field.

Designing 3D printable food based on fruit and vegetable products-opportunities and challenges

3D printing is an innovative technology for food industry, which provides tremendous opportunities for the designing of customized and personalized nutrition for fruit and vegetable based food products. Various researchers have worked on the development of printable ink, stability of printed products and quality parameters. The aim of this review is to cover the most recent advancements on 3D food printing for fruits and vegetables and explore the prospect. Extrusion-based 3D printing is the most extensively used technique due to their several advantages. The review examines the three groups of extrusion printing such as room temperature extrusion, fused deposition manufacturing and gel forming extrusion. The development in last few years in the area of 3D food products of fruits and vegetables powder has been assembled in this review article. Based on these results, it can conclude that fruit and vegetable has been successfully used to fabricate 3D and even 4D food products. Future studies are required for improvement in pre and post-processing technique. Functional food can also be developed by using 3D printing but more research is required in this area.

Supplementary Information

The online version contains supplementary material available at 10.1007/s13197-022-05386-4.

Texture modulation of starch-based closed-cell foams using 3D printing: Deformation behavior beyond the elastic regime

3-dimensional printing is a novel processing method used for the design and manipulation of food textures. The systematic characterization and modulation of 3D printed food textures is imperative for the future design of sensory profiles using additive manufacturing. For 3D printed closed-cell food foams, the clarification of the deformation behavior in relation to design parameters is of interest for the processing of customized food textures. For this reason, we studied the deformation behavior of 3D printed and thermally stabilized closed-cell starch-based foams beyond the elastic regime. Periodic spherical bubble configurations at different porosity levels were used to modulate the deformation behavior of the printed foams. From a processing perspective, the integration of in-line thermal stabilization was used to eliminate post-processing and to control the moisture content of the starch-based system. Compression analysis combined with FEM simulations were performed to characterize the strain rate dependency of textural properties, the stress relaxation, and the foam's stress-strain behavior with respect to the design porosity and bubble distribution. Results showed that the stress relaxation is solely dependent on cell wall properties while different stress-strain regimes showed distinct dependencies on design parameters such as bubble size and distribution. Consequently, the precise control of the large deformation behavior of foods using 3D printing is challenging due to the superposition of structural and geometrical dependencies. Finally, through the presented approach, the structure-deformation relations of 3D printed closed-cell food structures are adequately described.

Fabrication of Gastro-Floating Famotidine Tablets: Hydroxypropyl Methylcellulose-Based Semisolid Extrusion 3D Printing

Semisolid extrusion (SSE) three-dimensional (3D) printing uses drug-loaded paste for the printing process, which is capable of constructing intricate 3D structures. This research presents a unique method for fabricating gastro-floating tablets (GFT) using SSE. Paste-loaded famotidine with a matrix made of hydroxypropyl methylcellulose (HPMC) were prepared. Nine 3D printed tablets were developed with different HPMC concentrations and infill percentages and evaluated to determine their physicochemical properties, content uniformity, dissolution, and floating duration. The crystallinity of the drug remained unchanged throughout the process. Dissolution profiles demonstrated the correlation between the HPMC concentration/infill percentage and drug release behavior over 10 h. All the fabricated GFTs could float for 10 h and the Korsmeyer-Peppas model described the dissolution kinetics as combination of non-Fickian or anomalous transport mechanisms. The results of this study provided insight into the predictability of SSE 3D printability, which uses hydro-alcoholic gel-API blend materials for GFTs by controlling traditional pharmaceutical excipients and infill percentages. SSE 3D printing could be an effective blueprint for producing controlled-release GFTs, with the additional benefits of simplicity and versatility over conventional methods.

3D printing based on meat materials: Challenges and opportunities

Three-dimensional (3D) printing, as an emerging technology, is driving great progress in the food industry. In the meat field, 3D printing is expected to replace the traditional food industry and solve the problems of raw material waste and food contamination. Nevertheless, the application of 3D printing in meat still faces many challenges. The rheological properties of the ink, such as shear thinning behavior, viscosity, and yield stress, are critical in determining whether it can be printed smoothly and ensuring the quality of the product. Meat materials are complex multi-phase colloidal systems with unique fibrous structures that cannot be printed directly, and improving the printability of meat colloids mainly limits meat printing. The complexity of meat colloidal systems determines the different heat requirements. In addition, at this stage, the functionality of the printer and the formulation of a single nutritional and organoleptic properties limit the implementation and application of 3D printing. Moreover, the development of cultured meat, the full application of by-products, and the emergence of new technologies provides opportunities for the application of 3D printing in the meat industry. This review highlights the current challenges and opportunities for the application of 3D printing in meat to provide new ideas for the development of 3D printing.

An extrusion-based 3D food printing approach for generating alginate-pectin particles

In the present study, alginate-pectin (Al-P) hydrogel particles containing varied total gum concentrations (TGC) at a constant Al:P ratio of 80:20 were formed utilizing an innovative extrusion-based 3D food printing (3DFOODP) approach. The 3DFOODP conditions, namely, TGC (1.8, 2.0, and 2.2 wt%) and nozzle size (0.108, 0.159, and 0.210 mm) were investigated. The 3DFOODP approach was compared with the conventional bead formation method via a peristaltic pump. All Al-P printing inks exhibited a shear-thinning behavior. The increased apparent viscosity, loss and storage moduli were associated with the increase in the TGC. The size of the wet 3D-printed Al-P hydrogel particles ranged between 1.27 and 1.59 mm, which was smaller than that produced using the conventional method (1.44-1.79 mm). Freeze-dried Al-P particles showed a porous structure with reduced crystallinity. No chemical interaction was observed between alginate and pectin. This is the first report on generating Al-P-based beads using a 3DFOODP technique that can create delivery systems with high precision and flexibility.

Physicochemical Characterization of Texture-Modified Pumpkin by Vacuum Enzyme Impregnation: Textural, Chemical, and Image Analysis

Texture-modified pumpkin was developed by using vacuum enzyme impregnation to soften texture to tolerable limits for the elderly population with swallowing and chewing difficulties. The impregnation process and macrostructural and microstructural enzyme action were explored by the laser light backscattering imaging technique and a microscopic study by digital image analysis. Texture was analyzed by a compression assay. The effect of enzyme treatment on antioxidant capacity and sugar content was evaluated and compared to the traditional cooking effect. Image analysis data demonstrated the effectiveness of the impregnation process and enzyme action on plant cell walls. Enzyme-treated samples at the end of the process had lower stiffness values with no fracture point, significantly greater antioxidant capacity and significantly lower total and reducing sugars contents than traditionally cooked pumpkins. The results herein obtained demonstrate the capability of using vacuum impregnation treatment with enzymes to soften pumpkins and their positive effects on antioxidant capacity and sugar content to develop safe and sensory-accepted texture-modified products for specific elderly populations.

Impact of internal structural design on quality and nutritional properties of 3D printed food products during post-printing: a critical review

3D food printing (3DFP) provides an excellent opportunity to deposit layers of multiple food materials to create unique complex structures of products with more engaging visuals, specific textures, and customized nutritional properties. Many printed products require post-printing processing which can result in sensory variance, texture changes, and even nutritional modification. Hence it is necessary to implement the design of the complex internal structure to ensure the desired quality of the printed products following post-printing. 3-D printing of various types of food products, for example, chocolate, cheese, meat, vegetables, fruits, fish, eggs, cereal-based products, and so on, has been examined with regard to post-printing requirements. This review aims to summarize the current work on the latest developments in 3DFP technology concerning the internal structure design of 3D printed products and its effect on quality during post-printing. The quality parameters include: textural, physical, morphological, and dimensional characteristics as well as nutritional properties. Furthermore, post-printing modifications such as 4D are also analyzed.

Prospects of Polymeric Nanocomposite Membranes for Water Purification and Scalability and their Health and Environmental Impacts: A Review

Water shortage is a major worldwide issue. Filtration using genuine polymeric membranes demonstrates excellent pollutant separation capabilities; however, polymeric membranes have restricted uses. Nanocomposite membranes, which are produced by integrating nanofillers into polymeric membrane matrices, may increase filtration. Carbon-based nanoparticles and metal/metal oxide nanoparticles have received the greatest attention. We evaluate the antifouling and permeability performance of nanocomposite membranes and their physical and chemical characteristics and compare nanocomposite membranes to bare membranes. Because of the antibacterial characteristics of nanoparticles and the decreased roughness of the membrane, nanocomposite membranes often have greater antifouling properties. They also have better permeability because of the increased porosity and narrower pore size distribution caused by nanofillers. The concentration of nanofillers affects membrane performance, and the appropriate concentration is determined by both the nanoparticles' characteristics and the membrane's composition. Higher nanofiller concentrations than the recommended value result in deficient performance owing to nanoparticle aggregation. Despite substantial studies into nanocomposite membrane manufacturing, most past efforts have been restricted to the laboratory scale, and the long-term membrane durability after nanofiller leakage has not been thoroughly examined.

Starch as edible ink in 3D printing for food applications: a review

Three-dimensional (3D) printing has attracted more attention in food industry because of its potential advantages, including the ability to create customized products according to individual's sensory or nutritional requirements. However, the production of high-quality 3D printed foods requires the availability of edible bio-inks with the required physicochemical and sensory attributes. Starch, as one of the important sources of dietary energy, is widely used in food processing and is considered as one kind of versatile polymers. It is not only because starch has low prices and abundant sources, but also because desirable modified starch can be obtained by altering its physicochemical properties through physical, chemical and enzymatic methods. This article focuses on the utilization of starch as materials to create food-grade bio-inks. Initially, several kinds of commonly used 3D printers are discussed. The factors affecting the printing quality of starch-based materials and improvement methods are then reviewed, as well as areas where future researches are required. The applications of 3D printed starch-based materials in food industry are also introduced. Overall, starch appears to be one kind of useful substances for creating edible bio-inks that can be utilized within 3D food printing applications to create a wide variety of food products.

Preparing a Personalized Meal by Using Soy, Cricket, and Egg Albumin Protein Based on 3D Printing

Recently, personalized meals and customized food design by means of 3D printing technology have been considered over traditional food manufacturing methods. This study examined the effects of different proteins (soy, cricket, and egg albumin protein) in two concentrations (3% and 5%) on rheological, textural, and 3D printing characteristics. The textural and microstructural properties of different formulations were evaluated and compared. The addition of soy and cricket protein induced an increase in yield stress (τ₀), storage modulus (G′), and loss modulus (G″) while egg albumin protein decreased these parameters. The textural analysis (back extrusion and force of extrusion) demonstrated the relationship between increasing the amount of protein in the formula with an improvement in consistency and index of viscosity. These values showed a straight correlation with the printability of fortified formulas. 3D printing of the different formulas revealed that soy and cricket proteins allow the targeting of complex geometry with multilayers.

The sustainability of emerging technologies for use in pharmaceutical manufacturing

INTRODUCTION

Sustainability within the pharmaceutical industry is becoming a focal point for many companies, to improve the longevity and social perception of the industry. Both additive manufacturing (AM) and microfluidics (MFs) are continuously progressing, so are far from their optimization in terms of sustainability; hence, it is the aim of this review to highlight potential gaps alongside their beneficial features. Discussed throughout this review also will be an in-depth discussion on the environmental, legal, economic, and social particulars relating to these emerging technologies.

AREAS COVERED

Additive manufacturing (AM) and microfluidics (MFs) are discussed in depth within this review, drawing from up-to-date literature relating to sustainability and circular economies. This applies to both technologies being utilized for therapeutic and analytical purposes within the pharmaceutical industry.

EXPERT OPINION

It is the role of emerging technologies to be at the forefront of promoting a sustainable message by delivering plausible environmental standards whilst maintaining efficacy and economic viability. AM processes are highly customizable, allowing for their optimization in terms of sustainability, from reducing printing time to reducing material usage by removing supports. MFs too are supporting sustainability via reduced material wastage and providing a sustainable means for point of care analysis.

Towards the creation of personalized bakery products using 3D food printing

Bakery products with interesting color, shape and texture have been created using 3D food printing. Current research focuses on the development of new formulations and the optimization of the printing and post-printing treatment processes, in order to obtain high-quality 3D-printed bakery products. Knowledge about food rheology is useful for the development of dough formulations with good 3D-printability. Additives such as hydrocolloids could improve the printability of dough, and novel ingredients are introduced via 3D printing to produce functional bakery products with potential health benefits. One of the main future promises of 3D printing lies in its ability to produce bakery products that are personalized in terms of sensorial properties and nutritional composition, in order to meet the preferences and dietary requirements of individual consumers. This chapter addresses the most recent developments in 3D-printed bakery foods and highlights some important research topics to further advance this field.

Properties and Applications of Intelligent Packaging Indicators for Food Spoilage

Food packaging plays a vital role in the food supply chain by acting as an additional layer to protect against food contamination, but the main function of traditional conventional packaging is only to isolate food from the outside environment, and cannot provide related information about food spoilage. Intelligent packaging can feel, inspect, and record external or internal changes in food products to provide further information about food quality. Importantly, intelligent packaging indicators will account for a significant proportion of the food industry’s production, with promising application potential. In this review, we mainly summarize and review the upcoming progress in the classification, preparation, and application of food packaging indicators. Equally, the feasibility of 3D printing in the preparation of intelligent food packaging indicators is also discussed in detail, as well as the limitations and future directions of smart food packaging. Taken together, the information supported in this paper provides new insights into monitoring food spoilage and food quality.

Towards the Development of 3D-Printed Food: A Rheological and Mechanical Approach

Additive manufacturing, or 3D printing, has raised interest in many areas, such as the food industry. In food, 3D printing can be used to personalize nutrition and customize the sensorial characteristics of the final product. The rheological properties of the material are the main parameters that impact the 3D-printing process and are crucial to assuring the printability of formulations, although a clear relationship between these properties and printability has not been studied in depth. In addition, an understanding of the mechanical properties of 3D-printed food is crucial for consumer satisfaction, as they are related to the texture of food products. In 3D-printing technologies, each manufacturing parameter has an impact on the resulting mechanical properties; therefore, a thorough characterization of these parameters is necessary prior to the consumption of any 3D-printed food. This review focuses on the rheological and mechanical properties of printed food materials by exploring cutting-edge research working towards developing printed food for personalized nutrition.