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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 by growing mushroom mycelium on specially designed 3D-printed scaffolds made from wood and plant-based plastic. These mycelium bricks are stronger, better insulators, and more fire-resistant than traditional bricks or foam insulation, while being completely biodegradable. This breakthrough could help reduce the construction industry’s massive carbon footprint and provide a sustainable alternative to harmful conventional building materials.

Background

Mycelium-bound composites (MBCs) grown from fungi onto lignocellulosic substrates offer sustainable alternatives to petroleum-based construction materials. However, their limited mechanical strength and durability restrict practical applications in the construction industry, which currently accounts for 37% of global greenhouse gas emissions.

Objective

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

Results

Yield strength of 7.29 ± 0.65 MPa was achieved for 50% porosity MBC, with thermal conductivity of 0.012 W/mK for 90% porosity MBC. Maximum strength improvement of 50.4-77.7% was observed at medium to high porosity (70-90%). MBCs demonstrated superior thermal insulation compared to polyurethane foams and improved fire resistance with enhanced hydrophobicity.

Conclusion

Integration of 3D printing, scaffold design, and mycelium growth enables development of sustainable bio-based composites with superior mechanical and functional properties suitable for construction applications. The method provides tuneable strength and thermal properties while maintaining environmental sustainability and biodegradability.
  • Published in:Nature Communications,
  • Study Type:Experimental Research,
  • Source: 10.1038/s41467-025-61369-x, PMID: 40595784
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