Researchers Use Microalgae to 3D Print Fish-Like Textures — Could Replace Real Seafood

Researchers from Ewha Womans University and SuFAB Inc. in South Korea have developed a groundbreaking 3D printing food ink using Auxenochlorella protothecoides (white chlorella) that can simulate selected fish texture properties.

The Challenge of Plant-Based Seafood

Global seafood consumption has been increasing at nearly twice the rate of population growth, according to the UN Food and Agriculture Organization. This has contributed to overfishing, biodiversity loss, and exposure to contaminants like mercury and microplastics. Development of fish analogs has accelerated in response, typically relying on multi-component formulations based on plant proteins and hydrocolloids.

This study instead evaluates A. protothecoides, a white-pigmented microalga containing approximately 65% protein on a dry-matter basis, as a single-ingredient printable matrix. Its pale coloration supports visual alignment with white-fleshed seafood, addressing limitations associated with green microalgae.

The 36% Sweet Spot

Rheological measurements, printability tests, and texture profile analysis identified a 36% biomass concentration as the only formulation achieving stable extrusion and dimensional accuracy. Lower concentrations (32% and 34%) led to printed filaments spreading due to insufficient elastic resistance, while higher concentrations (38% and 40%) caused extrusion instability and nozzle clogging.

"WC 36% was identified as the practical optimum, providing sufficient post-deposition self-support without exceeding the extrusion limits of the printing system," the researchers state. Dimensional analysis confirmed zero percent error in both height and width relative to the CAD design at this concentration.

Matching Real Fish Textures

Texture profile analysis compared printed samples with steamed mackerel, flounder, and salmon using hardness and cohesiveness as metrics. The results were impressive:

• Mackerel-like hardness was achieved using either a 0.85mm nozzle at 30% infill or a 0.5mm nozzle at 60% infill
• Flounder and salmon targets were reached using alternative configurations

The study, published in the LWT journal, demonstrates that 3D printing can produce textured seafood alternatives from a single sustainable ingredient source.

Why This Matters

This research represents a significant step toward sustainable seafood alternatives. Using microalgae as a single-ingredient matrix simplifies production compared to complex plant-protein formulations, while the ability to match specific fish textures could accelerate consumer adoption of lab-grown seafood alternatives.