X-TRUDE: A Process-Informed Framework for High-Fidelity Analysis of Hydrogel Extrusion

Reliable extrusion of viscoelastic hydrogels is crucial for technologies ranging from 3D (bio)printing to injectable therapeutics, yet current methods to characterize extrusion performance fail to mimic key processing conditions. Consequently, extrusion performance cannot be precisely predicted or controlled, particularly for emerging thermosensitive, shear-thinning, or heterogeneous hydrogels. Fundamentally, reliable extrusion is an emergent outcome of intrinsic materials properties coupled to extrinsic processing conditions. Here, we introduce X-TRUDE, a process-informed characterization platform that recapitulates the spatiotemporal conditions of the extrusion process by integrating in situ pressure sensing, controlled thermal conditions, and process-relevant flow-path geometries. X-TRUDE reveals extrusion-specific phenomena inaccessible with conventional methods, including the transient evolution of apparent rheological response and time-local instabilities such as heterogeneity-induced variations in extrudate morphology. Across monolithic, thermosensitive, and granular hydrogel formulations, X-TRUDE establishes temporal pressure fluctuation patterns as quantitative metrics to unravel mechanisms underlying extrusion variability and correlate pressure profiles with extrudate morphology. By linking intrinsic rheology with the physical extrusion environment, X-TRUDE provides a quantitative, mechanistic framework to benchmark extrudability across soft matter systems. This framework enables more reliable formulation development, reduces failure during process translation, and offers a generalizable tool for extrusion-based technologies in biofabrication, therapeutic delivery, and soft material manufacturing.