Use of a coaxial nozzle-assisted 3D printing and ionic crosslinking to control the texture of a mycoprotein-based food product

• Co-axial assisted 3D food printing combined with in-situ ionic crosslink allows texture personalisation. • Filamentous Aspergillus oryzae biomass enables the development of texture personalised food products. • Co-axial 3D food printing allows the development of fibrous food structures. • The crosslinker gluconolactate allows the creation of a soft food structure with a fibrous texture. • The produced samples met the IDDSI requirements for dysphagia food levels 5, 6 and 7. This work innovatively merges engineered food structures with additive manufacturing technology to tailor food for different dysphagia levels using filamentous Fungus Aspergillus oryzae biomass through a co-axial 3D food printing process. In order to 3D print samples with different textures, calcium chloride (CaCl 2 ) and calcium gluconolactate (Gluco) were tested at different concentrations alongside three alginate concentrations. The structural and morphological analysis of the printed samples was conducted before cooking, followed by texture analysis and the measurement of cutting strength on cooked samples. Dysphagia food level classification was measured following the International Dysphagia Diet Standardisation Initiative (IDDSI) guidelines. Results revealed that Gluco minimally altered texture but affected appearance, resulting in soft samples (hardness ≈ 1.3 N) with fibrous structures, while CaCl 2 increased hardness (from ≈ 1 N to 4.68 N) through alginate-ion Ca 2+ interaction. All samples passed the IDDSI test, confirming suitability for dysphagic individuals. This successfully engineered personalised food with tailored texture meeting nutritional requirements.