Single-use plastic packaging must be eliminated, as its impact on planetary health is huge, since it does not degrade and soon turns into microplastic particles. This has led to the development of edible and biodegradable packaging alternatives. This study presents an integrated edible packaging system that combines microalgae- and macroalgae-based components using 3D food printing technology. Edible cups were formulated using Chlorella vulgaris biomass and 3D-printed with a helical ridge design to increase their surface area, enhance adhesion of subsequent edible hydrocolloid coatings and reduce permeability.

Aqueous extracts of hydrocolloids from Chondrus crispus were used to develop the coatings, either as a control or enriched with lipid extracts or glycerol. This strategy enables the principles of 'Clean Label' to be maintained while hydrocolloids are still used as crucial ingredients.

Chemical analyses were conducted to determine the antioxidant potential (FRAP, DPPH and ABTS assays). Mechanical properties, water vapor permeability, and light barrier properties were also evaluated for the edible films.

The results showed that incorporating C. vulgarisadded structure to the 3D 'ink', resulting in improved extrusion and better shape fidelity. This was crucial in enabling the accurate printing of the ridged cup structure. This design retained significantly more coating — over 170% more than the smooth-walled control cup. Not only did the C. crispus hydrocolloid coatings add a protective barrier, improving UV resistance, mechanical integrity and water permeability control, they also contributed additional antioxidant activity to the final product.

The printed matrix and the hydrocolloid-based surface coating worked synergistically to produce fully edible, nutrient-rich, functional, clean-label packaging. This work demonstrates how formulation and design can be optimised together to develop sustainable, completely biodegradable, clean-label packaging with enhanced structural and nutritional performance.