Structure design of an innovative 3-dimensional-printed emulsion carrier for stabilizing polyunsaturated fatty acids in krill oil

Antarctic krill oil ( AKO ), rich in polyunsaturated fatty acids ( PUFAs ) such as EPA and DHA , is limited in food applications due to its physicochemical instability. We develop a 3D -printed carrier system incorporating small-clustered water ( SCW ) prepared layer-by-layer ( LBL) emulsion with potato starch and potato protein to enhance the stability of PUFAs in AKO . The SCW-LBL emulsion formed a compact structure with a smaller median particle size ( d 0.5  = 0.130 μm) than regular water ( RW )-based emulsions. 3D -printed SCW -emulsion carriers exhibited lower loss modules and lower viscosity in oscillatory frequency-sweep tests, which are likely associated with SCW -induced restructuring of hydrogen bonds and charge interactions, suggesting the formation of a more compact network. Printing tests confirmed that SCW -emulsion carriers improved stability and fidelity by reducing gravity-driven sedimentation. Thermal stability analysis showed SCW -emulsion carriers slowed PUFAs degradation, with higher activation energy ( E a ) and thermal resistance. Under light exposure, 3D -printed SCW -emulsion carriers displayed reduced photodegradation rates, increased photodegradation activation energy ( E p ), and enhanced the stability of AKO . Moreover, the total antioxidant capacity ( T-AOC ) of SCW -emulsion carriers increased by 7.3-8.2% compared to RW -emulsions after 8 h. This suggests that SCW may facilitate the reduction of emulsion droplet size, potentially through promoting tighter hydration and a more compact starch-protein matrix, which contributes to improved oxidation stability. Therefore, the 3D -printed SCW - LBL emulsion carrier system can be utilized by food and nutraceutical manufacturers to produce PUFA -enriched products with enhanced thermal, photochemical, and oxidative stability, as well as superior structural fidelity.