Micro-aeration has been employed by the chocolate industry as a texture and flavour modifier. However, the impact of micro-aeration on oral processing is still not well understood. This study quantifies the mechanical, thermal and tribological behaviour of chocolate materials of different porosity levels. These material properties were then linked to sensory data considering the temporal phenomena of the oral process. In-vivo mastication tests were utilised to define the level of fragmentation of chocolate and coupled with heat transfer numerical models to simulate the melting during oral processing. Micro-aeration affects all material properties resulting in lower fracture stresses, rapid melting and a lower friction coefficient. The sensory results showed that micro-aeration creates a perception of a softer, less sticky chocolate which melts fast inside the mouth, without compromising the sweetness perception. This research adopts an innovative multidisciplinary approach to the physics of chocolates, bringing together the fields of solid mechanics, heat transfer, tribology, and sensory analysis and employing engineering experimental and numerical approaches to provide a link between chocolate structure, material properties and sensory perception. The outcome can contribute a powerful design tool for controlling the perception of sensory attributes for specific chocolate composition.