PLA

The Inner World of the Portafilter Coffee enthusiasts often talk about "even extraction" as the holy grail of brewing, but the reality inside the basket remains largely a matter of speculation. Most baristas rely on external cues—the flow rate, the color of the stream, or the taste of the final cup—to guess what is happening to the coffee bed. James Hoffmann recently partnered with Lumafield to remove the guesswork using computed tomography. By applying industrial x-ray technology to espresso pucks, we can finally see the internal density variations and structural flaws that define a successful shot. Computed Tomography Meets Coffee Science Industrial CT scanning works by rotating an object 360 degrees while an x-ray emitter captures its density from every angle. The resulting data builds a 3D model composed of voxels—volumetric pixels—that reveal cross-sections of the internal structure. In the context of coffee, this allows for the identification of clumps, air pockets, and density gradients that are invisible to the naked eye. Scanning coffee presents unique technical hurdles. Metal filter baskets absorb too much x-ray energy, requiring long, 12-hour scan times to resolve the tiny coffee particles. To bypass this, researchers used 3D-printed PLA baskets, which are far more transparent to x-rays. This clarity revealed that even high-end grinders, like the Monolith, produce distinct internal structures based on how the grounds are handled before tamping. The Anatomy of Distribution and Clumping When examining a puck from a consumer-grade Breville grinder, the scans showed significant clumping throughout the basket. Interestingly, these clumps were more prevalent around the edges and the top. While tamping compresses the bed, it does not necessarily eliminate these dense clusters. The scans proved that clumps survive even under pressure, creating localized areas of high resistance that force water to find alternative paths. Advanced distribution techniques showed varied results. Tools like the AutoComb left behind faint vertical needle paths in the loose grounds, though these appeared to vanish after tamping. More surprisingly, using a shaking cup—a method often praised for increasing extraction—actually created small, high-density clusters. This suggests that while shaking might homogenize the overall grind, it can also cause particles to adhere to one another in unexpected ways. The Structural Collapse of Spent Pucks Analyzing a spent puck—one that has already been brewed—revealed the violent physics of the espresso machine. Most modern machines, including the Decent Espresso model used in the test, feature a three-way solenoid valve. This valve instantly depressurizes the group head once the shot ends. The CT scans showed that this sudden release of pressure causes the puck to expand upward, creating massive horizontal cracks. This makes it nearly impossible to see vertical "channels" formed during brewing, as the post-shot expansion destroys the evidence. To truly visualize a channel in its native state, one would need to use a lever machine, which allows pressure to dissipate naturally without the jarring suction of a solenoid valve. Implications for the Modern Barista These scans challenge the assumption that a tamped puck is a uniform block of coffee. Every puck examined showed a density gradient, with the top third appearing less dense than the bottom. This internal landscape dictates how water moves through the coffee. Understanding that our tools—whether needles or shakers—leave a physical footprint inside the puck is the first step toward more scientific, repeatable brewing. The hidden world inside the portafilter is far more chaotic than it looks from the outside.