Repurposing FDM Printers for 3D Food Printing: Experimental Study with Commercial Pastes

3D food printing is an innovative technological advancement capable of transforming food value chains into systems that are both consumer-focused and sustainable. Its potential lies in enabling on-demand food production, allowing automated and geometrically complex customization, and reducing food waste throughout the entire supply chain—from agricultural production to industrial processing, retail, and household consumption. According to recent research by Precedence Research, the global market for 3D food printing is estimated to be valued at USD 534.75 million in 2025, with projections indicating a substantial growth to approximately USD 7,569.93 million by 2034. Over time, 3D printing has become increasingly accessible and cost-effective. However, despite decreasing costs, the initial investment in a 3D food printer remains a significant barrier, particularly for small businesses and households. This study aimed to evaluate the efficiency of a syringe extruder mechanism (SEM) adapted from a Creality Ender S1 Pro 3D printer, originally designed for 1.75 mm thermoplastic filaments, and converted into a functional 3D paste printer. Printing tests were performed using Repetier Host software with star (five-pointed) and square designs, a printing speed of F300, and a layer height of 6 mm. Commercial pastes - tuna (TP), chocolate and almond (CAP), cream cheese (CC), pepper jelly (PJ), and mixed sample (MCC: 65% CAP + 35% cream cheese) - were evaluated. Image analysis was conducted in ImageJ to measure structural uniformity. For star design, the measurement considers the tip-to-tip distance, which was marked with a line segment, and also traces an oval format around the star to produce a histogram. For square shapes, the distance of the internal vertex was measured, with line segments and histograms were made to trace a rectangle/square format around the design. The mean tip-to-tip distance for star designs ranged from 47.1 mm (CC) to 237.4 mm (MCC), and internal vertex distances for square designs varied from 21.8 mm (TP) to 147.1 mm (MCC). Histogram analysis revealed that both design geometry and paste composition affected the uniformity of printed structures. These findings demonstrate that the modification of a standard 3D printer using SEM is a promising approach for enhancing the versatility and accessibility of 3D-printed foods.