3D food printing (3DFP) is an emerging novel technology in food fabrication, capable of creating food constructs with a layer-by-layer technique based on the desired design. The flexibility of this new technology offers the freedom to customise any preferred design. Among various type of 3D printing techniques, extrusion method is favourable to print the majority of fresh and edible foods. This method allows fresh foods in a paste, or liquid form to be extruded through the nozzle. Understanding the food material characteristic is the major factor that needs to be considered in choosing substrates for 3DFP. Dark chocolate was used as the main material in this work. It composed of cocoa butter (fat), cocoa solids, sugar, and lecithin. The important constituent in chocolate is cocoa butter (fat) containing the stable b-crystals in the chocolate matrix. These crystal fats help the chocolate to retain its quality such as glossy appearance, smooth texture and will set even after its being partially melted maintaining the b-crystal nuclei during printing. Extrusion method (auger) was applied in this work as the primary method to print the chocolate in powder form. Also, the addition of additive in auger extrusion is required to act as a flow enhancer, minimising the occurrence of slip-effect. Various physical properties, including analysing the effect of food additives, modification of internal structure, sensorial and potential consumersr perception and acceptance of 3D printed chocolates, were evaluated during this research work.At the beginning of this work, several modifications to a commercial 3D printer were required. The modification included developing a new 3D printer bed, water re-circulating system and the attachment of an air blower. A custom stainless steel printer bed (200 mm x 200 mm x 10 mm) was designed with an in-built water recirculation system (flow rate of 6.3 mL/s and maintain the temperature at ~16 oC).n Also, the printer bed was supported by a custom stabiliser printed by 3D filament printer using a plastic filament (Acrylonitrile Butadiene Styrene ABS). Additionally, an air blower was attached to avoid condensation that may occur on the printer bed due to cooling below room temperature. These modifications were done to ensure that the extruded chocolate solidifies efficiently upon extrusion. The optimisation of printing parameters was executed to determine the nozzle height and printing temperature. A series of comprehensive analysis including thermal properties, flow properties and tribological properties of printed chocolate was conducted. The original chocolate and the printed chocolate had a similar thermal melting profile (average melting peak of 32.9 p 0.3 dC) as analysed by DSC suggesting that the printed chocolate had similar crystal forms. Food grade additives, magnesium stearate (Mg-ST) and native plant sterol (PS) were investigated for their suitability as a flow enhancer to reduce the slip-effect of the powdered chocolate movement in the auger extrusion. The findings suggested that Mg-ST and PS did not influence the thermal and flow properties of the printed chocolate. However, tribology analysis indicated that chocolate samples with additives showing a higher coefficient of friction, possibly due to the effect of particle size.The 3D printer has the capability of modifying the internal structure of a food construct. In this study, 3D food printer was utilised to alter the internal construct structure (5%, 30%, 60% and 100%) infill percentage-IP (star, Hilbert curve and honeycomb infill patterns) to modify the textural properties of 3D printed chocolate. The void fraction of the printed constructs become lesser as IP increased from 5% to 100%. A higher force (N) was required to break the constructs with high IPs. Chocolate printed with Hilbert curve pattern required less force to break the samples (regardless of infill percentages, from 5% to 60% IP) ranging from 1.9 p 0.1 N to 11.7 p 0.7 N. For the same variation of infill percentages, the force required to break the samples printed with star pattern and honeycomb pattern ranged from 6.1 p 0.2 N to 45.3 p 1.4 N and 9.0 p 0.3 N to 47.4 p 0.5 N, respectively. Honeycomb and star infill pattern exhibited more interlayer bonding zones than that of Hilbert curve infill pattern producing a tougher 3D printed chocolates. The mechanical strength of the cast sample was higher (required g110 N) as compared to printed chocolate (100% IP). The results demonstrate that IPs influence the mechanical strength of 3D printed chocolate, indicating a textural change of the chocolate. In the sensorial perspective, texture modified chocolate (printed in a honeycomb pattern with various infill percentage 25%, 50% and 100%) was given to panellist (age between 28 and 55 years) to assess their preferences based on appearance and texture of the printed chocolate. The panellist suggested that the appearance of 3D printed chocolate (100% IP) was favourable and indicated their preferences for chocolate printed in 25% IP. A similar preference of cast chocolate and 3D printed chocolate samples in 100% infill percentage was obtained. Consumer perception was obtained by the 3D printer and printed chocolate samplesr display and using a survey questionnaire to assess their knowledge, perceived benefit and their attitudes towards 3DFP. The finding prominently indicated that most of the consumers in the investigated community (University of Queensland premises) were aware of 3D food printing technology. The display of 3D food printing contributed positive feedback from consumers as 3D printed dark chocolate samples were visible to the participants of the survey. These results demonstrated the positive attitudes of consumers toward 3D food printing technology.