The presently disclosed subject matter is directed to a system and method of preparing personalized nutritional and/or pharmaceutical formulations using additive manufacturing technology. Active pharmaceutical or dietary supplement ingredients are suspended in thixotropic stable carrier medias. The thixotropic suspensions are deposited onto a surface of a solid substrate, which can be a snack bar or small wafer used as a mechanical carrier. The disclosed system enables each additive active ingredient to be variably dosed based on a formula that is determined for each specific individual and manufactured on demand. Once the active ingredients are deposited on substrate, the entire assembly can be enrobed with one or more edible solid coatings to seal the active ingredients and provide taste-masking agent characteristics to the assembly.