Additive Timber Manufacturing: A Novel, Wood-Based Filament and Its Additive Robotic Fabrication Techniques for Large-Scale, Material-Efficient Construction

Wood-Veneer-Reinforced Mycelium Composites for Sustainable Building Components

The demand for building materials has been constantly increasing, which leads to excessive energy consumption for their provision. The looming environmental consequences have triggered the search for sustainable alternatives. Mycelium, as a rapidly renewable, low-carbon natural material that can withstand compressive forces and has inherent acoustic and fire-resistance properties, could be a potential solution to this problem. However, due to its low tensile, flexural and shear strength, mycelium is not currently widely used commercially in the construction industry. Therefore, this research focuses on improving the structural performance of mycelium composites for interior use through custom robotic additive manufacturing processes that integrate continuous wood fibers into the mycelial matrix as reinforcement. This creates a novel, 100% bio-based, wood-veneer-reinforced mycelium composite. As base materials, Ganoderma lucidum and hemp hurds for mycelium growth and maple veneer for reinforcement were pre-selected for this study. Compression, pull-out, and three-point bending tests comparing the unreinforced samples to the veneer-reinforced samples were performed, revealing improvements on the bending resistance of the reinforced samples. Additionally, the tensile strength of the reinforcement joints was examined and proved to be stronger than the material itself. The paper presents preliminary experiment results showing the effect of veneer reinforcements on increasing bending resistance, discusses the potential benefits of combining wood veneer and mycelium's distinct material properties, and highlights methods for the design and production of architectural components.