The Interconnection Between 3D and 4D Printing and Rheology: From Extrusion and Nozzle Deposition to Final Product Functionality

The successful application of 3D and 4D food printing is fundamentally governed by the rheology and microstructure of edible inks. These factors control every step, from extrusion and nozzle deposition to the final product functionality. This review systematically examines how formulation variables, including starch/protein composition, water content, and hydrocolloids, determine the network architecture and critical rheological properties, such as yield stress and viscoelasticity. These properties determine printing outcomes such as filament formation, stacking accuracy, and the stability of sensitive components. This review explores 4D printing as a “3D + 1D function,” where printed structures provide additional features over time, such as a controlled color change or bioactive release, while post-printing treatment often activates these features. Through case studies of novel inks, we show how interfacial chemistry and process parameters influence texture and stability. Finally, we discuss the application of rheological metrics for predicting printability and outline the critical need for developing multi-parameter, process-relevant printability indices to advance the field of digital food manufacturing.