Optimization of chocolate 3D printing by correlating thermal and flow properties with 3D structure modeling

Abstract 3D printing is a new promising technology capable of creating intricate food shapes. To stabilize the mechanical properties of the complex printed food it may require support structures. The 3D shape of chocolate was designed with different support structures (cross support, parallel support and no support) and its effect on the snapping properties was investigated. This study also determined the relationship between the physical properties of chocolate used for printing and the quality of the printed 3D constructs. The dimensions (wall thickness, height, and diameter), weight as well as physical properties (melting properties, flow behaviour, snap ability) of the 3D printed chocolate were evaluated. The nozzle temperature before deposition was maintained at 32 °C in order to extrude the melted state of the sample as the flow behaviour curves indicated that the melting of chocolate started between 28 °C to 30 °C. Incorporation of Magnesium Stearate (MgST) in the chocolate formulation aid in material lubrication and increase flow efficiency during deposition. Results showed that there was a minor difference between the predetermined diameter and the actual output diameter for each sample suggesting similarity between the printed 3D structure and the pre-designed 3D model. Wall thickness of printed item varied along the height due to uneven deposition of chocolate as the layer height increased. The breaking strength of the sample was strongly related to the additional support structure, with 3D chocolate with cross support structure requiring the highest force (N) to break the sample. Industrial relevance The development and production of food with 3-Dimensional printing (3DP) technology has potential to create and produce food in a more advanced format that will be a new paradigm shift in the food industry. Through 3D printing, personalised food can be created in terms of shape and nutritional composition. To firmly establish this promising technology as a powerful tool for engineering food it is required a thorough understanding of the supply ingredients and strategies to enhance printability. This study demonstrates the use of flow enhancer and inclusion of support structure in the designed shape were key factors influencing printability capacity of chocolate (edible ink chosen as a model).