A method and material for 3D printing objects containing heat-sensitive molecules are disclosed. The composition consists of a water-saturated, polar
thermoplastic polymer, such as highly hydrolyzed
polyvinyl alcohol (PVA), into which functional molecules—proteins, peptides, pharmaceuticals, fragrances, or living cells—are dispersed. The
polymer is first hydrated to form a gel, extruded and
cut into
pellets, then partially dried through a multi-stage
dehydration process that leaves a
moisture-rich core and a dry outer shell. During
extrusion at typical FDM
nozzle temperatures (≈200° C.), entrapped water within the material vaporizes at ≈100° C., providing in situ evaporative cooling and maintaining the temperature of the functional molecules below their degradation point. The process enables additive manufacturing of structurally sound objects that preserve the activity of heat-sensitive additives, opening new applications for 3D-printed
consumables, pharmaceuticals, and bio-functional components.