Development and evaluation of plant-based 3D-printed oral dispersible films for personalized nutrition for athletes

In athletes, perspiration depletes reserves of minerals and electrolytes and oxidative stress increases with effort, and is accompanied by muscle fatigue, cellular damage, and impaired immunity. Athletes often use artificial supplements in order to correct mineral deficiency; however, they also pose risks related to bioavailability and potential toxicity. However, it is emphasized that sports nutrition is not a one-size-fits-all solution, as each athlete has specific nutritional needs. Hence, nutritional customization with 3D food printing can allow for the creation of tailored food for individual athletes. In the present investigation, oral disintegrating films (ODFs) were developed through extrusion-based 3D printing using extracts of Alternanthera sessilis; Sauropus androgynous, popularly known as multivitamin plant leaves; and extracts of the fruit Momordica dioica combined with HPMC K4M/E5, pullulan, moringa gum, ghatti gum, glycerol, roselle calyx powder, and fructo-oligosaccharide. The fabricated ODFs displayed consistent thicknesses (0.228 ± 0.008 mm to 0.340 ± 0.012 mm), rapid disintegration (15.23 ± 0.53 to 36.545 ± 0.65 s), and strong organoleptic scores (92.4 ± 1.60 to 91.2 ± 4.18/100). Moisture content (7.50 ± 0.13 to 6.154 ± 0.21%) and swelling index (26.68 ± 0.92 to 40.40 ± 2.80%) supported stability and mucosal compatibility. SEM images of all formulations revealed a uniform matrix with irregular depressions. FTIR confirmed functional groups such as C–O–C, phenolic O–H, and carbonyls, common among all the formulations, with H-bonded O-H bond vibration in sauropus-based films. ICP-MS identified macro elements such as K: 568.21, Na: 222.92, Mg: 72.23, and Ca: 19.74 mg/100g in Alternanthera-based ODFs; K: 137.41, Na: 218.15, Mg: 151.11, and Ca: 32.95 mg/100g in Sauropus; and K: 537.34, Na: 187.09, Mg: 65.65, and Ca: 37.97 mg/100g in Momordica-based films, and trace microelements Fe, Zn, Cu, Se, Mn, Cr, and Co were also identified. A. sessilis-based ODFs showed superior physicochemical traits, while Sauropus-based ODFs exhibited comparatively high mineral content, and 136 distinct phytonutrients (phytochemicals) with potential antioxidant potential, confirming their promise as sustainable, bioactive carriers for personalized nutrient delivery in athletes.