SBIR-STTR Award

This Small Business Innovation Research Phase I project seeks to address the steadily growing but unsustainable polymer matrix composite (PMC) market. PMCs are leveraged for their high strength-to-weight and stiffness-to-weight ratios as compared to conventional engineering materials, but are notoriously unsustainable, energy-intensive to manufacture, and non-recyclable. Researchers have investigated encapsulating natural fibers with both petroleum-based polymers and biopolymers (e.g. cellulosic plastic) to produce more biocompatible composites with varying degrees of experimental and commercial success, but all attempts have still fallen short of an ideal "bio-composite". In this project, we will create and characterize an entirely new bio-composite material. The basic idea is to use mycelium as a matrix for binding natural fibers and core filler materials together in sustainable composite parts. First, the core bulk material is bound together over time by mycelium growing into and around common bulk agricultural waste such as cotton hulls. Then, reinforcing layers made from natural fibers (e.g., hemp) inoculated with fungal cells are applied to the core faces, allowed to infiltrate the laminate and bind to the core material, and then heated to inactivate the growth process to make a resilient composite sandwich structure. The broader impact/commercial potential of this project encompasses the development of mycelium composite materials that are customizable for a broad range of markets including, but not limited to, automotive, transportation, architectural, biomedical, sports, and recreation. These materials are truly sustainable since both the laminates and cores consist of renewable materials. These composites will also require significantly less energy to make than other biocompatible composites because the material is grown instead of synthesized, and the material is completely compostable at the end of life. The outcome of the proposed research and development will be a basic understanding of how to manufacture the composites, the range of material properties obtainable, and how to adjust material properties for particular markets. Through this project, we will partner with researchers and students at two local universities with known expertise in composites manufacturing and testing. If successful with mycelium composites, these materials will find applications in a very high-margin market (i.e. composites) that is sorely needing more sustainable innovations

This Small Business Innovation Research (SBIR) Phase II project seeks to further quantify the mechanical performance of mycological bio-composites that address the automotive and structural core industries, while concurrently scaling and demonstrating material production. The engineered composites market continues to grow steadily because of the high strength-to-weight and stiffness-to-weight ratios of these systems, as compared to conventional engineering materials. Engineered woods are ubiquitous in the construction and furniture industries, but due to domestic indoor air quality regulations (Toxic Substances Control Act), these materials are being phased out or are forced to use expensive formaldehyde-free adhesives. Similarly, the automotive industry is under regulatory pressure in Europe to find alternatives to fire-retardant foams that cannot be recycled due to inorganic filling agents. The technical results from the Phase I effort have demonstrated bio-composite materials which can compete both economically, and on mechanical performance, with the aforementioned competitors, while meeting these legislative demands. A preliminary cost analysis based on the process economics of our existing production facilities projects retail costs 45% and 35% below the current state-of-the-art in the automotive and furniture industries, respectively. We will work with key industry partners to meet performance metrics and demonstrate quality pilot production. The broader impact/commercial potential of this project would be a customizable bio-composite for a broad range of markets, including automotive, transportation, architectural, furniture, sports, and recreation. These materials are truly sustainable, since both the laminates and cores used in the sandwich structure consist of renewable materials. They also require significantly less energy to make than other biocompatible composites, because the material is grown instead of synthesized, and the material is completely compostable at the end of life. The outcome of the proposed development and demonstration will ensure that the bio-composite properties meet the requirements for the target markets. Furthermore, over the course of this grant, and in cooperation with Rensselaer and Union College, we will demonstrate and scale the best manufacturing processes to a pilot stage capable of manufacturing high volumes of quality product. Since these materials leverage regional lignocellulosic byproducts from domestic agriculture and industry, a regional manufacturing model is presently being pursued to reduce transportation and feedstock costs. This will not only bring additional value to U.S. agricultural markets, but will spur rural economic development through domestic manufacturing. Finally, these advanced biological materials represent a new paradigm in manufacturing, offering safe, biodegradable alternatives to traditional petroleum-based alternatives.