Sensory characterisation and volatile analysis of 3D-printed dairy protein-based snack structures

3D food printing (3DFP) enables personalized nutrition, texture, and macrostructure in food design. Dairy protein powders are common ingredients used in 3DFP due to their structure-forming properties. This study evaluated the sensory profile of two dairy-based 3D-printed snack structures made using whey or milk protein isolates (WPI or MPI) to gain insights into their sensory perception and aroma. The volatile compounds (VCs) were analyzed using gas chromatography-mass spectrometry. A trained sensory panel assessed the snacks using quantitative descriptive analysis. Texture profile analysis (TPA) and microstructure observation via confocal laser microscopy were also conducted. Over 90% of the identified VCs were typical of dairy ingredients. Sensory scores from the evaluation panel revealed the greatest differences among the snacks. WPI-based snacks were higher in sourness (7.0/10) and stickiness (6.3/10), while MPI-based snacks had stronger milk powder notes (6.2/10). TPA confirmed significant texture differences across all parameters (p < .05) between the two snack structures, attributed to their different protein composition and microstructural properties. This study demonstrates that the distinct sensory and aroma properties of the 3D-printed snacks provide a basis for complementary flavors, such as chocolate for MPI-based and strawberry for WPI-based 3D-printed snacks.