Research progress on plant-based protein materials in food 3D printing: forming mechanisms, stabilization mechanisms, and applications

Abstract

The integration of plant-based foods with 3D printing technology offers a revolutionary solution for addressing future food security, sustainable manufacturing, and personalized nutrition. However, the inherent rheological limitations and processing instabilities of native plant proteins remain critical bottlenecks restricting their widespread adoption in additive manufacturing. This review aims to systematically summarize the research progress of plant protein-based materials across three primary food 3D printing technologies: Binder Jetting (BJT), extrusion-based printing, and inkjet printing. First, the forming and stabilization mechanisms under different printing modes are critically analyzed, focusing on the powder–binder interfacial wetting in BJT, the shear-thinning and thixotropic recovery of emulsion gels in extrusion, and the piezoelectric jettability and rapid gelation kinetics of hydrogels in inkjet printing. Second, strategies to optimize the printability of plant proteins via molecular modification (e.g., enzymatic hydrolysis, covalent/non-covalent cross-linking) and multi-scale structural design (e.g., polysaccharide complexation, bimodal particle size distribution) are elaborated. The review further showcases innovative applications in whole-cut meat analogues, personalized dysphagia diets, and functional bioactive carriers. Finally, the challenges regarding food safety (microbial and allergen risks), regulatory lag, and consumer acceptance are critically discussed. Future perspectives highlight the immense potential of multi-material co-extrusion, 4D printing, and Artificial Intelligence (AI)-driven inverse formulation design in accelerating the industrialization of plant-based food 3D printing.