3D extrusion printability of corn starch and optimization of process parameters for optimal food layered manufacturing
Rahul Soni, Vivek V. Bhandarkar, K. Ponappa, Puneet Tandon
Abstract
Food Layered Manufacturing (FLM) combines additive manufacturing with culinary science to create personalized, sustainable food products. This study explores the 3D printability of corn starch as a food ink for FLM, focusing on optimizing its rheological, textural, and color properties to enhance printability and support eco-friendly food production. A corn starch-based food ink was formulated and tested using a developed extrusion-based 3D food printer equipped with IoT protocols for remote monitoring and real-time defect detection, ensuring consistent quality and reliability. The rheological analysis demonstrated the ink is non-Newtonian, with shear-thinning behavior, allowing smooth extrusion and stable layer formation essential for complex food structures. Texture and color evaluations revealed its ability to produce aesthetically pleasing and firm textured food items. Key printing parameters, such as nozzle diameter (1.5 mm) and printing speeds (50–60 mm/s), were optimized to balance material flow, cohesion, and resolution while minimizing defects like layer breakage or overflow. The findings establish corn starch as a promising FLM material for producing customizable food products with enhanced nutritional and aesthetic value. This research underscores FLM’s potential to revolutionize food production, reduce waste, utilise renewable resources, and contribute to global sustainability efforts aligned with the United Nations’ Sustainable Development Goals.