Investigating Rheological Behavior of Chlorella vulgaris Starch: Implications for 3D Printable Bioplastic Material

The increasing demand for sustainable materials in additive manufacturing has driven the development of bioplastics derived from renewable biomass, including microalgae. In this study, the rheological behavior of a 20 wt.% aqueous gel prepared from native Chlorella vulgaris (C. vulgaris) starch, plasticized with 30 wt.% glycerol, was investigated to assess its suitability for extrusion-based 3D printing (direct-ink-writing, DIW). Steady shear analysis revealed a pronounced yield stress (τ0 = 271.93 Pa) and strong shear-thinning behavior, described by the Herschel–Bulkley model (K = 59.47 Pa·sn, n = 0.67), indicating structural stability at rest and efficient flow under shear. Oscillatory measurements confirmed a predominantly elastic response, with storage modulus (G′ ≈ 13,500 Pa) greatly exceeding loss modulus (G″) and a low loss factor (tan δ≈ 0.1), demonstrating gel integrity and shape retention. Temperature-dependent analysis indicated enhanced network strength without thermal softening, while thixotropic recovery tests showed rapid structural rebuilding after shear removal. Notably, a ~50% increase in G′ during recovery highlights improved interlayer adhesion potential. These results show that C. vulgaris starch exhibits the key rheological characteristics required for DIW-type extrusion printing, including yield stress, shear-thinning behavior, viscoelastic stability, and rapid recovery, making it a promising candidate for this application.