Assessing the viability of producing nixtamalised foods through additive manufacturing and rheological analysis

Abstract This study assesses the feasibility of producing nixtamalised foods through additive manufacturing, examining the relationship between masa composition, rheology, and performance in 3D printing. Commercial blue, white, and yellow nixtamalised flours were tested to create printable formulations (65% water/35% flour ratio). The results showed pseudoplastic behaviour of hydrated masas (Tanδ < 0.21), with elastic properties (G′ > 11,709 Pa) dominating over viscous ones. Significant differences in rheological properties and printability across the flour types were found. Yellow masa exhibited the highest viscosity and elasticity, while blue masa demonstrated superior 2D printability with the lowest percentage of error (16.7%). However, 3D structures printed with blue masa faced higher deformation due to their rheological limitations, including lower viscosity coefficient (ƞ = 32,832 Pa•s) denoting higher water absorption. Pearson correlation analysis revealed that viscosity influences retrogradation, while the crowding and packing factors correlate (R2 > 0.99) with particle distribution and compaction within the masa. The Einstein–Roscoe equation was applied (p <0.001), elucidating the relationship between particle interactions and viscosity that agreed with the data obtained from the viscoelastic Maxwell model. This study examines the application of additive manufacturing in the production of nixtamalised foods, focusing on the impact of the masa’s structure, rheological properties, and its behaviour during 3D printing.