Recent technological innovations in mycelium materials as leather substitutes: a patent review

Leathery mycelium materials, made from the vegetative part of filamentous fungi, have garnered significant interest in recent years due to their great potential of providing environmentally sustainable alternatives to animal- and plastic-based leathers. In this systematic patent review, we provide an in-depth overview of the fabrication methods for mycelium materials as leather substitutes recently described in patents. This overview includes strategies for fungal biomass generation and industrial developments in the sector. We discuss the use of various fungal species, plasticizers, crosslinking agents, and post-processing techniques, thereby highlighting potential gaps in scientific knowledge and identifying opportunities, challenges, and concerns in the field. Our analysis suggests that mycelium materials have significant potential for commercialization, with a growing number of companies betting on this new class of biomaterials. However, we also reveal the need for further scientific research to fully understand the properties of these materials and to unlock potential applications. Overall, this patent review delineates the current state of the art in leathery mycelium materials.

BioKnit: development of mycelium paste for use with permanent textile formwork

This paper presents significant advances in mycelium biofabrication using permanent knitted textile formwork and a new substrate formulation to dramatically improve the mechanical properties of mycelium-textile biocomposites suitable for large-scale components for use in construction. The paper outlines the biofabrication process, detailing the composition of mycocrete, a viscous mycelium substrate developed for use with permanent knitted formwork, and the injection process required to regulate the filling of slender tubes of fabric with mycocrete. The use of a permanent integrated knitted formwork shows promise as a composite system for use with mycelium to improve mechanical performance and enable complex shapes to be fabricated for lightweight construction. Results of mechanical testing show dramatic improvements in tensile, compressive and flexural strength and stiffness compared to conventional mycelium composites. The testing demonstrates the importance of both the mycocrete paste recipe and the knitted textile formwork. In addition, the paper highlights the advantages of the proposed biofabrication system with reference to the BioKnit prototype: a 1.8 m high freestanding arched dome composed of very slender biohybrid knit-mycelium tubes. This prototype demonstrates the opportunity to utilize the potential for lightweight construction and complex form offered by a textile formwork with low environmental impact mycelium biomaterials. The combination of textiles and mycelium present a compelling new class of textile biohybrid composite materials for new applications within the construction sector.

Current state and future prospects of pure mycelium materials

In the context of the ongoing transition from a linear to a circular economy, ecologically friendly renewable solutions are put in place. Filamentous fungi can be grown on various organic feedstocks and functionalized into a range of diverse material types which are biobased and thus more sustainable in terms of their production, use and recycling. Pure mycelium materials, consisting only of mycelial biomass, can adopt versatile properties and appear promising as a substitute for current petrochemically produced polymeric materials or, in the case of myco-leather, as a substitute for animal-based leather. In recent years, a handful of private companies have been innovating to bring products based on pure mycelium materials to the market while scientific interest in these promising biomaterials is now starting to gain momentum. In this primer, we introduce pure mycelium materials, frame different production methods, review existing and potential future applications, thereby offering a vision on future advances for this emerging fungi-based technology.

Mechanical characteristics of bacterial cellulose-reinforced mycelium composite materials

BACKGROUND

While mycelium is considered a promising alternative for fossil-based resins in lignocellulosic materials, the mechanical properties of mycelium composite materials remain suboptimal, among other reasons due to the weak internal bonds between the hyphae and the natural fibres. A solution could be provided by the hybridisation of mycelium materials with organic additives. More specifically, bacterial cellulose seems to be a promising additive that could result in reinforcing mycelium composites; however, this strategy is underreported in scientific literature.

RESULTS

In this study, we set out to investigate the mechanical properties of mycelium composites, produced with the white-rot fungus Trametes versicolor, and supplemented with bacterial cellulose as an organic additive. A methodological framework is developed for the facile production of bacterial cellulose and subsequent fabrication of mycelium composite particle boards based on a hybrid substrate consisting of bacterial cellulose and hemp in combination with a heat-pressing approach. We found that, upon adding bacterial cellulose, the internal bond of the composite particle boards significantly improved.

CONCLUSIONS

The addition of bacterial cellulose to mycelium composite materials not only results in a strengthening of internal bonding of mycelium material, but also renders tuneable mechanical properties to the material. As such, this study contributes to the ongoing development of fully biological hybrid materials with performant mechanical characteristics.

A review on the potential of filamentous fungi for microbial self-healing of concrete

Concrete is the most used construction material worldwide due to its abundant availability and inherent ease of manufacturing and application. However, the material bears several drawbacks such as the high susceptibility for crack formation, leading to reinforcement corrosion and structural degradation. Extensive research has therefore been performed on the use of microorganisms for biologically mediated self-healing of concrete by means of CaCO₃ precipitation. Recently, filamentous fungi have been recognized as high-potential microorganisms for this application as their hyphae grow in an interwoven three-dimensional network which serves as nucleation site for CaCO₃ precipitation to heal the crack. This potential is corroborated by the current state of the art on fungi-mediated self-healing concrete, which is not yet extensive but valuable to direct further research. In this review, we aim to broaden the perspectives on the use of fungi for concrete self-healing applications by first summarizing the major progress made in the field of microbial self-healing of concrete and then discussing pioneering work that has been done with fungi. Starting from insights and hypotheses on the types and principles of biomineralization that occur during microbial self-healing, novel potentially promising candidate species are proposed based on their abilities to promote CaCO₃ formation or to survive in extreme conditions that are relevant for concrete. Additionally, an overview will be provided on the challenges, knowledge gaps and future perspectives in the field of fungi-mediated self-healing concrete.

A comprehensive framework for the production of mycelium-based lignocellulosic composites

Environmental pollution and scarcity of natural resources lead to an increased interest in developing more sustainable materials. For example, the traditional construction industry, which is largely based on the extraction of fossil fuels and raw materials, is called into question. A solution can be found in biologically augmented materials that are made by growing mycelium-forming fungal microorganisms on natural fibres rich in cellulose, hemicellulose and lignin. In this way, organic waste streams, such as agricultural waste, are valorised while creating a material that is biodegradable at the end of its life cycle - a process that fits in the spirit of circular economy. Mycelium-based materials have properties that are promising for a wide range of applications, including the use as construction materials. Despite this promise, the applicability and the practicality of these materials are largely unexplored and moreover, individual studies use a wide range of different experimental approaches and non-standardized procedures. In this review, we critically evaluate existing data on the composition of mycelium-based materials and process variables with the aim of providing a comprehensive framework of the production process. The framework illustrates the many input factors during the production that have an impact on the final characteristics of the material, and the unique potential to deploy more tuneable levels in the fabrications process that can serve to prototype a diversity of new unprecedented applications. Furthermore, we determine the applicability of existing data and identify knowledge gaps. This framework is valuable in identifying standardized approaches for future studies and in informing the design and process of new applications of mycelium-based materials.

Mechanical, physical and chemical characterisation of mycelium-based composites with different types of lignocellulosic substrates

The current physical goods economy produces materials by extracting finite valuable resources without taking their end of the life and environmental impact into account. Mycelium-based materials offer an alternative fabrication paradigm, based on the growth of materials rather than on extraction. Agricultural residue fibres are inoculated with fungal mycelium, which form an interwoven three-dimensional filamentous network binding the feedstock into a lightweight material. The mycelium-based material is heat-killed after the growing process. In this paper, we investigate the production process, the mechanical, physical and chemical properties of mycelium-based composites made with different types of lignocellulosic reinforcement fibres combined with a white rot fungus, Trametes versicolor. This is the first study reporting the dry density, the Young’s modulus, the compressive stiffness, the stress-strain curves, the thermal conductivity, the water absorption rate and a FTIR analyse of mycelium-based composites by making use of a fully disclosed protocol with T. versicolor and five different type of fibres (hemp, flax, flax waste, softwood, straw) and fibre processings (loose, chopped, dust, pre-compressed and tow). The thermal conductivity and water absorption coefficient of the mycelium composites with flax, hemp, and straw have an overall good insulation behaviour in all the aspects compared to conventional materials such as rock wool, glass wool and extruded polystyrene. The conducted tests reveal that the mechanical performance of the mycelium-based composites depends more on the fibre processing (loose, chopped, pre-compressed, and tow), and size than on the chemical composition of the fibres. These experimental results show that mycelium-composites can fulfil the requirements of thermal insulation and have the potential to replace fosile-based composites. The methology used to evaluate the suitability and selection of organic waste-streams proved to be effective for the mycelium-material manufacturing applications.