Metamaterials Enable Scalable Production of Realistic Plant-Based Meat

Israeli and Palestinian engineers from The Hebrew University of Jerusalem have made groundbreaking strides in sustainable food production by using advanced metamaterials to replicate the texture and structure of whole cuts of meat. Published in Nature Communications, this innovative work demonstrates how materials science can transform alternative protein manufacturing, moving beyond the limitations of 3D printing and other conventional methods. Spearheaded by Dr. Mohammad Ghosheh and Prof. Yaakov Nahmias, the project has achieved a significant milestone in creating high-quality meat analogs through scalable, cost-effective processes, offering a potential solution to some of the most pressing challenges in modern food systems.

Metamaterials are engineered composites with properties determined by their structure rather than their intrinsic composition. These materials are commonly used in advanced applications such as aerospace engineering. By applying such principles to food technology, the researchers developed meat analogs capable of closely mimicking the intricate texture of muscle fibers and the melting characteristics of animal fat. Utilizing injection molding—a manufacturing process adapted from the polymer industry—the team successfully mass-produced meat substitutes that retain the sensory and structural qualities of traditional steaks, chops, and other complex meat cuts.

The development hinged on two innovative metamaterials. The first, called low-temperature meat analog (LTMA), mimics the fibrous structure of muscle tissue with high precision. This material replicates the unique chewiness and texture of animal muscle, an element notoriously difficult to reproduce in plant-based or cultured alternatives. The second, proteoleogel (PtoG), is a plant-protein-stabilized oleogel designed to emulate the melting behavior and mouthfeel of animal fat. The combination of these materials allows for the creation of a unified product that performs as well as traditional meat in taste, texture, and cooking dynamics.

One of the most significant breakthroughs of this research lies in its scalability. Current 3D printing methods for creating meat analogs, while promising, remain slow and prohibitively expensive for large-scale food production. Injection molding, however, is capable of producing these products rapidly and at much lower costs. The researchers estimate that their technology reduces production expenses to $9 per kilogram—approximately one-fourth the cost of meat analogs made through 3D printing. This dramatic cost reduction could democratize access to high-quality plant-based protein alternatives, making them a viable option for more consumers around the world.

Blind taste tests conducted as part of the research underscored the potential of this innovation to change consumer perceptions of meat substitutes. Participants in these tests were unable to reliably distinguish between traditional meat cuts and those created using LTMA and PtoG. The sensory likeness to conventional meat suggests that these products can appeal not only to vegetarians and vegans but also to the broader demographic of omnivorous consumers seeking sustainable options without compromising on taste or texture.

“This is a pivotal moment for alternative protein technologies,” remarked Prof. Yaakov Nahmias. “Our work with metamaterials opens a new chapter in food production, marrying advanced materials science with culinary demands. By designing foods with precision at the molecular level, we can tackle critical environmental and economic challenges posed by traditional livestock farming.”

Livestock agriculture has a profound impact on global resources and the environment. It accounts for more than 30% of the world’s freshwater use and generates approximately 15% of greenhouse gas emissions. The intensification of meat production to meet rising global demand exacerbates deforestation, soil degradation, and biodiversity loss. Consequently, sustainable meat analogs are not merely a culinary curiosity—they represent a necessity for the planet’s ecological future.

The use of injection molding further enhances the environmental benefits of this innovation. The high-capacity production method reduces waste and energy consumption, making it more sustainable than both traditional meat production and earlier plant-based meat manufacturing techniques. Furthermore, the ability to craft whole cuts of meat analogs addresses a gap in the alternative protein market, where most current offerings focus on simpler forms such as ground meat or burgers. With whole cuts comprising over half of global meat consumption, this research targets a critical sector that has remained largely unmet in the transition to plant-based diets.

Beyond its environmental implications, this advancement also holds cultural and economic promise. Many cuisines around the world celebrate whole cuts of meat as centerpieces of traditional dishes. By providing a sustainable and equally satisfying alternative, the researchers envision their work complementing, rather than replacing, culinary traditions while simultaneously addressing global food security issues.

In addition to its technical achievements, this project also symbolizes the power of collaboration in addressing global challenges. The combined efforts of Israeli and Palestinian engineers underscore the potential of cross-border cooperation in scientific innovation. Together, the researchers have forged a pathway for a more inclusive and sustainable food future, highlighting the role of shared knowledge and technology in solving issues that affect humanity as a whole.

The study’s impact stretches beyond the realm of food technology. It underscores the versatility of metamaterials, offering a glimpse into their potential applications in other domains where structural and functional optimization is paramount. As Prof. Nahmias notes, “This is just the beginning of what metamaterials can achieve in food and beyond. We’ve developed materials that bridge the gap between science and the sensory experience, and this opens the door to endless possibilities.”

With global meat consumption continuing to rise and the planet grappling with the environmental toll of traditional agriculture, innovations like this represent a crucial step toward sustainable solutions. The ability to produce affordable, high-quality meat analogs could reduce the strain on natural resources while offering consumers delicious, familiar food options. This convergence of materials science, engineering, and gastronomy redefines not just how we create food, but how we think about sustainability in the face of growing global challenges.

By introducing groundbreaking metamaterials and scalable production techniques, the research team at Hebrew University has paved the way for the next generation of plant-based meat substitutes. The fusion of advanced engineering and culinary tradition in their work exemplifies the innovation needed to build a sustainable and equitable food system, ensuring that high-quality protein remains accessible to all while protecting the planet for generations to come.

Reference: Mohammad Ghosheh et al, Metamaterial-based injection molding for the cost-effective production of whole cuts, Nature Communications (2024). DOI: 10.1038/s41467-024-54939-y