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The Development and Optimization of Extrusion-Based 3D Food Printing Inks Using Composite Starch Gels Enriched with
Evgenia N Nikolaou1, Eftychios Apostolidis1, Eirini K Nikolidaki1
1Department of Science of Dietetics-Nutrition, Harokopion University, 70, El. Venizelou, Kallithea, 17671 Athens, Greece.
Gels (Basel, Switzerland)
|August 28, 2025
Summary
This study optimized starch-based food inks for 3D printing using proteins and hydrocolloids. κ-carrageenan formulations showed superior printability and texture, advancing personalized 3D food printing.
Area of Science:
- Food Science and Technology
- Materials Science
- Biotechnology
Background:
- 3D food printing (3DFP) offers personalized nutrition but requires optimized food inks.
- Starch-based gels are promising but need enhanced rheological and textural properties.
- Incorporating proteins and hydrocolloids can modify ink performance for extrusion-based 3DFP.
Purpose of the Study:
- To comprehensively evaluate starch-based gel formulations with proteins and hydrocolloids for 3DFP.
- To systematically analyze rheological, mechanical, and textural properties influencing printability.
- To establish a data-driven framework for optimizing printable food gels.
Main Methods:
- Preparation of food inks using corn/potato starch, various protein concentrates, and hydrocolloids (κ-carrageenan, arabic gum, xanthan gum, carboxy methylcellulose).
- Systematic analysis of rheological (viscoelasticity, yield stress), mechanical, and textural properties.
- Validation using Computational Fluid Dynamics (CFD) simulations and Fourier-transform infrared spectroscopy (FTIR).
Main Results:
- Formulations with κ-carrageenan exhibited superior viscoelasticity (G' > 4000 Pa), optimal tan δ (0.096-0.169), and suitable yield stress for stable extrusion.
- Achieved high structural fidelity (93-96% accuracy) and improved textural attributes (hardness, chewiness).
- CFD simulations correlated ink performance with rheological parameters; FTIR confirmed non-covalent interactions strengthen gels.
Conclusions:
- κ-carrageenan is highly effective in enhancing starch-based ink printability and texture for 3DFP.
- A combined approach of empirical testing and CFD simulation provides a robust method for food ink optimization.
- Findings support the development of advanced personalized and functional 3D-printed foods.

