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3D printed gyroid scaffolds enabling strong and thermally insulating mycelium-bound composites for greener infrastructures

Summary

Scientists developed a new eco-friendly building material made from mushroom mycelium grown on 3D-printed scaffolds. This material is as strong as traditional bricks, provides excellent insulation like foam, resists fire better than conventional materials, and is completely compostable. The innovation could help reduce carbon emissions from construction by replacing harmful petroleum-based and energy-intensive traditional building materials.

Background

Mycelium-bound composites (MBCs) grown from fungi onto lignocellulosic substrates offer sustainable alternatives to petroleum-based materials and conventional construction materials like clay bricks. However, their limited mechanical strength, poor durability, and uneven mycelium growth have restricted their practical applications in the construction industry.

Objective

To develop strong and thermally insulating mycelium-bound composites by growing mycelium onto 3D-printed stiff wood-polylactic acid (PLA) porous gyroid scaffolds, enhancing mechanical properties while imparting functional properties like thermal insulation, fire resistance, and hydrophobicity.

Results

The MBCs achieved yield strength of 7.29 ± 0.65 MPa and thermal conductivity as low as 0.012 W/mK at 90% porosity. Maximum improvement in yield strength (50.4-77.7%) was observed at medium-to-high porosity levels. The composites demonstrated superior thermal insulation compared to polyurethane foams, enhanced fire resistance through char production, improved hydrophobicity with contact angles up to 130.93°, and excellent durability over 300 days when inactive.

Conclusion

Integration of 3D printing, gyroid scaffold design, and mycelium growth successfully produces bio-based composites with balanced strength-to-weight ratios and multifunctional properties suitable for sustainable construction applications. These MBCs outperform conventional materials like clay bricks and polyurethane foams while maintaining compostability and low manufacturing energy requirements.
  • Published in:Nature Communications,
  • Study Type:Experimental Research,
  • Source: 10.1038/s41467-025-61369-x, PMID: 40595784
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