3D Printed Freeze-Dried Hydrogels for Probiotic Viability

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Solution Overview

Problem

Existing 3D printing technologies face challenges in maintaining the viability of probiotics due to the permanent shape-change of biopolymers, which affects the survival of microorganisms during manufacturing, storage, and digestion, and there is a need for shelf-stable probiotic-containing products that cater to diverse health needs and are compatible with 3D printing methods.

Innovation Solution

Development of 3D printable edible hydrogels that are freeze-dried, comprising a probiotic, such as Bifidobacterium spp., Lactobacillus spp., or Lactococcus spp., which are crosslinked, printed, and then freeze-dried to maintain viability and stability, using methods like droplet-based, extrusion-based, or stereolithography bioprinting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If biopolymers are used as hydrogels for 3D printing, then the material is biocompatible and suitable for probiotic encapsulation, but the ionic crosslinks break and re-form during straining causing permanent shape-change that reduces probiotic viability

Engineering Contradiction:

Improveprobiotic viabilityVSAvoidhydrogel shape stability

Core Design Contradiction:

Object-affected harmful factorsVSStability of the object's composition

Solution Approach 1:

The patent changes the crosslinking mechanism from ionic to covalent bonding, fundamentally altering the chemical parameters of the hydrogel system. This transformation eliminates the dynamic breakage and reformation of bonds that occurs with ionic crosslinks, providing stable shape retention during 3D printing while maintaining probiotic viability.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite hydrogel system combining gelatin and alginate with distinct functional roles: gelatin provides covalent crosslinking for structural stability, while alginate provides biocompatibility and probiotic protection. This composite approach resolves the contradiction by integrating the beneficial properties of both materials while eliminating their individual limitations.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If conventional 3D printing is used with probiotic-containing hydrogels, then the manufacturing process is simple and cost-effective, but the probiotics do not survive manufacturing and storage conditions

Engineering Contradiction:

Improve3D printing simplicityVSAvoidprobiotic survival rate

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent incorporates probiotics into the hydrogel matrix before the 3D printing process, performing the encapsulation action in advance. This preliminary encapsulation protects probiotics during subsequent printing and storage operations, ensuring their survival without complicating the manufacturing process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The hydrogel matrix serves as a protective cushion for probiotics before they are exposed to harsh manufacturing and storage conditions. This beforehand protection allows conventional 3D printing methods to be used while maintaining high probiotic viability throughout the product lifecycle.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Shape

If hydrogels are printed with high viscosity materials, then the printed structure maintains shape fidelity, but the extrusion process becomes difficult and requires high pressure

Engineering Contradiction:

Improveprinted structure fidelityVSAvoidextrusion processability

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The patent utilizes the dynamic rheological properties of the hydrogel, exploiting its shear-thinning behavior where viscosity decreases under extrusion shear stress and increases at rest. This dynamic response allows easy extrusion during printing while maintaining shape fidelity after deposition, resolving the contradiction between processability and structural accuracy.

Inventive Principle:

Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The hydrogels are shelf-stable for at least 3 months with a probiotic viability of at least 106 CFU/g, ensuring the survival of probiotics through manufacturing and storage conditions, and are compatible with various 3D printing mechanisms.

Implementation Method 1

crosslinking the hydrogel precursor into a hydrogel

Methodology Applied

Scientific EffectCrosslinking: Chemical Bonding

Implementation Method 2

freeze-drying the hydrogel

Methodology Applied

Scientific EffectFreeze-drying: Freeze Drying

Data Source

PatentUS12403163B23D printed, freeze-dried hydrogels and methods of making and using the same

Publication Date: 2025.09.02 IOWA STATE UNIV RES FOUND INC

AI summary

The present disclosure relates to food grade hydrogels containing probiotics and methods of their preparation. More particularly, this disclosure describes 3D printable edible hydrogels, freeze-dried 3D printed edible hydrogels, systems for their printing, as well as, methods of preparing food grade 3D printed, freeze dried hydrogel compositions. Beneficially, the 3D printed, freeze-dried hydrogel compositions are storage stable.