Boosting the role of complex food structure on oral breakdown and sweetness perception by digitally designed and 3D printed biscuits

Notwithstanding the growing demand for foods with reduced sugar content, the goal remains challenging due to the substantial role of sugar in sensory attributes. The present study was intended to investigate the structural properties of low-sugar biscuits, specifically texture and microstructure, and their impacts on oral breakdown during mastication and related sensory perception. 3D food printing with varying nozzle diameter, infill path, and shape was used to accurately deposit a cereal-based food formula. Biscuits obtained with 1.2 mm nozzle and with ‘trihexagonal’ infill pattern were noted to be harder than those printed with nozzle of 0.6 mm and with ‘gyroid’ pattern. The higher hardness depended not only on total porosity but also on the dimensional distribution of solid elements and voids. The total duration and number of peaks of the mastication cycle as well as maximum amplitude, evaluated via electromyography, showed higher values in the case of biscuits prepared with 1.2-mm nozzle and hand-made biscuits. Sensory test results demonstrated that samples with 0.6-mm filaments and with ‘gyroid’ pattern were perceived sweeter than all other samples. PCA confirmed intricate connections among all investigated aspects and how textural and microstructural characteristics could affect sweetness perception. • Biscuits with low sugar content were obtained with 3D food printing technology. • Biscuits with 1.2 mm filaments and trihexagonal infill path showed the highest hardness. • The sweetest samples were obtained with a 0.6 mm nozzle and with a ‘gyroid’ path. • Smaller nozzle diameters of 0.6 mm significantly affected the mastication behaviour. • Reduced hardness and size distribution of solid phase increase sweetness perception.