Tilted Arch; Implementation of Additive Manufacturing and Bio-Welding of Mycelium-Based Composites

Three-Dimensional Printing Using Biomass-Fungi Composite Materials: Brief Retrospective and Prospective Views

Petroleum-derived plastic materials are used to manufacture a wide range of products [...].

Biowelding 3D-Printed Biodigital Brick of Seashell-Based Biocomposite by Pleurotus ostreatus Mycelium

Mycelium biocomposites are eco-friendly, cheap, easy to produce, and have competitive mechanical properties. However, their integration in the built environment as durable and long-lasting materials is not solved yet. Similarly, biocomposites from recycled food waste such as seashells have been gaining increasing interest recently, thanks to their sustainable impact and richness in calcium carbonate and chitin. The current study tests the mycelium binding effect to bioweld a seashell biocomposite 3D-printed brick. The novelty of this study is the combination of mycelium and a non-agro-based substrate, which is seashells. As well as testing the binding capacity of mycelium in welding the lattice curvilinear form of the V3 linear Brick model (V3-LBM). Thus, the V3-LBM is 3D printed in three separate profiles, each composed of five layers of 1 mm/layer thickness, using seashell biocomposite by paste extrusion and testing it for biowelding with Pleurotus ostreatus mycelium to offer a sustainable, ecofriendly, biomineralized brick. The biowelding process investigated the penetration and binding capacity of the mycelium between every two 3D-printed profiles. A cellulose-based culture medium was used to catalyse the mycelium growth. The mycelium biowelding capacity was investigated by SEM microscopy and EDX chemical analysis of three samples from the side corner (S), middle (M), and lateral (L) zones of the biowelded brick. The results revealed that the best biowelding effect was recorded at the corner and lateral zones of the brick. The SEM images exhibited the penetration and the bridging effect achieved by the dense mycelium. The EDX revealed the high concentrations of carbon, oxygen, and calcium at all the analyzed points on the SEM images from all three samples. An inverted relationship between carbon and oxygen as well as sodium and potassium concentrations were also detected, implying the active metabolic interaction between the fungal hyphae and the seashell-based biocomposite. Finally, the results of the SEM-EDX analysis were applied to design favorable tessellation and staking methods for the V3-LBM from the seashell-mycelium composite to deliver enhanced biowelding effect along the Z axis and the XY axis with <1 mm tessellation and staking tolerance.

Three-Dimensional Printing of Living Mycelium-Based Composites: Material Compositions, Workflows, and Ways to Mitigate Contamination

The construction industry makes a significant contribution to global CO₂ emissions. Material extraction, processing, and demolition account for most of its environmental impact. As a response, there is an increasing interest in developing and implementing innovative biomaterials that support a circular economy, such as mycelium-based composites. The mycelium is the network of hyphae of fungi. Mycelium-based composites are renewable and biodegradable biomaterials obtained by ceasing mycelial growth on organic substrates, including agricultural waste. Cultivating mycelium-based composites within molds, however, is often wasteful, especially if molds are not reusable or recyclable. Shaping mycelium-based composites using 3D printing can minimize mold waste while allowing intricate forms to be fabricated. In this research, we explore the use of waste cardboard as a substrate for cultivating mycelium-based composites and the development of extrudable mixtures and workflows for 3D-printing mycelium-based components. In this paper, existing research on the use of mycelium-based material in recent 3D printing efforts was reviewed. This review is followed by the MycoPrint experiments that we conducted, and we focus on the main challenges that we faced (i.e., contamination) and the ways in which we addressed them. The results of this research demonstrate the feasibility of using waste cardboard as a substrate for cultivating mycelia and the potential for developing extrudable mixtures and workflows for 3D-printing mycelium-based components.

Mycelium-Composite Materials-A Promising Alternative to Plastics?

Plastic waste inefficiently recycled poses a major environmental concern attracting attention from both civil society and decision makers. Counteracting the phenomenon is an important challenge today. New possibilities are being explored to find alternatives to plastics, and one of them refers to mycelium-composite materials (MCM). Our study aimed at investigating the possibility of using wood and litter inhabiting basidiomycetes, an underexplored group of fungi that grow fast and create strong mycelial mats, to produce biodegradable materials with valuable properties, using cheap by-products as a substrate for growth. Seventy-five strains have been tested for their ability to grow on low-nutrient media and to form compact mycelial mats. Eight strains were selected further for evaluation on several raw substrates for producing in vitro myco-composites. The physico-mechanical properties of these materials, such as firmness, elasticity and impermeability, were analyzed. Abortiporus biennis RECOSOL73 was selected to obtain, at the laboratory scale, a real biodegradable product. Our results suggest that the strain used is a promising candidate with real possibilities for scalability. Finally, corroborating our results with scientific available data, discussions are being made over the feasibility of such technology, cost-effectiveness, scalability, availability of raw materials and, not least, where future studies should be directed to.

Strategies for Growing Large-Scale Mycelium Structures

Fungi-based materials (myco-materials) have been celebrated and experimented with for their architectural and structural potential for over a decade. This paper describes research applied to assembly strategies for growing large building units and assembling them into efficiently formed wall prototypes. A major concern in the development of these two fabrication strategies is to design re-usable formwork systems. La Parete Fungina demonstrates two undulating wall units standing side-by-side, each composed of seventeen myco-welded slabs. L’Orso Fungino revisits the in situ monolithic fabric forming of units that are repeated, stacked, and post-tensioned. Although the design and research presented in this paper focuses on overcoming the challenges of growing large-scale building components, this work also touches on issues of accessibility and technology, economic and logistical systems needed for building-scale applications, and material ethics of energy and waste associated with emerging biomaterial production.

Mycelium-Based Composite Graded Materials: Assessing the Effects of Time and Substrate Mixture on Mechanical Properties

Mycelium-based composites (MBC) are biodegradable, lightweight, and regenerative materials. Mycelium is the vegetative root of fungi through which they decompose organic matter. The proper treatment of the decomposition process results in MBC. MBC have been used in different industries to substitute common materials to address several challenges such as limited resources and large landfill waste after the lifecycle. One of the industries which started using this material is the architecture, engineering, and construction (AEC) industry. Therefore, scholars have made several efforts to introduce this material to the building industry. The cultivation process of MBC includes multiple parameters that affect the material properties of the outcome. In this paper, as a part of a larger research on defining a framework to use MBC as a structural material in the building industry, we defined different grades of MBC to address various functions. Furthermore, we tested the role of substrate mixture and the cultivation time on the mechanical behavior of the material. Our tests show a direct relationship between the density of the substrate and the mechanical strength. At the same time, there is a reverse relation between the cultivation time and the material mechanical performance.

Transcalar Design: An Approach to Biodesign in the Built Environment

Biodesign holds the potential for radically increasing the sustainability of the built environment and our material culture but comes with new challenges. One of these is the bridging of the vast differences of scale between microbiological processes and architecture. We propose that a transcalar design approach, which weaves together nonlinear dependencies using computational design tools and design methodologies through the biological generation of architectural components, is a way towards successful design implementations. Such design processes were explored in a laboratory-based fabrication and study of a column element. This column, named Protomycokion, serves to illustrate how design methodologies, particularly through the use of a demonstrator artefact, can serve to navigate the multiple scales, disciplines, and experiments that are necessary to engage the complexities of biodesign. Transcalar design processes embrace the adaptability, variability and interdependence of biological organisms and show possible gains with regard to material sustainability and increased performativity.

Risk assessment of fungal materials

Sustainable fungal materials have a high potential to replace non-sustainable materials such as those used for packaging or as an alternative for leather and textile. The properties of fungal materials depend on the type of fungus and substrate, the growth conditions and post-treatment of the material. So far, fungal materials are mainly made with species from the phylum Basidiomycota, selected for the mechanical and physical properties they provide. However, for mycelium materials to be implemented in society on a large scale, selection of fungal species should also be based on a risk assessment of the potential to be pathogenic, form mycotoxins, attract insects, or become an invasive species. Moreover, production processes should be standardized to ensure reproducibility and safety of the product.

BioMateriOME: To understand microbe-material interactions within sustainable, living architectures

BioMateriOME evolved from a prototyping process which was informed from discussions between a team of designers, architects and microbiologists, when considering constructing with biomaterials or human cohabitation with novel living materials in the built environment. The prototype has two elements (i) BioMateriOME-Public (BMP), an interactive public materials library, and (ii) BioMateriOME-eXperimental (BMX), a replicated materials library for rigorous microbiome experimentation. The prototype was installed into the OME, a unique experimental living house, in order to (1) gain insights into society's perceptions of living materials, and (2) perform a comparative analysis of indoor surface microbiome development on novel biomaterials in contrast to conventional indoor surfaces, respectively. This review summarizes the BioMateriOME prototype and its use as a tool in combining microbiology, design, architecture and social science. The use of microbiology and biological components in the fabrication of biomaterials is provided, together with an appreciation of the microbial communities common to conventional indoor surfaces, and how these communities may change in response to the implementation of living materials in our homes. Societal perceptions of microbiomes and biomaterials, are considered within the framework of healthy architecture. Finally, features of architectural design with microbes in mind are introduced, with the possibility of codifying microbial surveillance into design and construction benchmarks, standards and regulations toward healthier buildings and their occupants.