Additive layer manufacturing (ALM) is an emerging technology for production of complex three-dimensional objects in the food sector. In this study, semi-hard model cheeses with different calcium levels (15.8 +/- 0.9 to 31 +/- 2 mg Ca g(-1) protein) were produced to investigate thermorheological properties and shear behavior at large strain to set up process parameters for hot-melt extrusion based ALM. The gel-sol transition temperature (51.7 +/- 0.2 to 60 +/- 2 degrees C) significantly (P < 0.001) decreased with declining calcium levels. Hence, extrusion die temperature was set to 60 degrees C in capillary rheometer experiments to mimic hot-melt extrusion based ALM. The extrudate strands were evaluated visually and recorded pressure profiles were analyzed to determine critical shear rates. It was demonstrated that critical shear rate (10-30 s(-1)) increased significantly (P < 0.001) with decreasing calcium levels and with increasing flowability (tan delta 60 degrees C). By exceeding the critical shear rate, extrusion instabilities occurred indicating limitation of ALM processes. (C) 2018 Elsevier Ltd. All rights reserved.