Systems and methods for fabricating fungal mycelium-based consumer products

Abstract

A method (500) of forming a consumer product using a mycelium cultivation system (100) includes forming a mold (400), casting a porous growth substrate (102) from the mold (400), inducing mycelial growth on the porous growth substrate (102) to form a mycelial growth structure, and separating the mycelial growth structure from the porous growth substrate (102).

Description

SYSTEMS AND METHODS FOR FABRICATING FUNGAL MYCELIUM-BASED CONSUMER PRODUCTSCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 572,187 filed March 30, 2024, the entirety of which is hereby incorporated by reference.TECHNICAL FIELD

[0002] The present application relates to fungus cultivation, and more particularly to fabricating consumer products directly through the cultivation of basidiomycetes onto customized molds.BACKGROUND

[0003] This section introduces aspects that may help facilitate a better understanding of the disclosure. Accordingly, these statements are to be read in this light and are not to be understood as admissions about what is or is not prior art.

[0004] Mushrooms hold immense significance across various domains, from culinary delights to medical breakthroughs. With a rich history spanning cultures and civilizations, mushrooms have not only served as a nutritional source but have also contributed to traditional medicine and cultural practices. Beyond their culinary allure, mushrooms are known for their ecological role as essential decomposers in natural ecosystems, aiding in nutrient cycling and maintaining the balance of ecosystems. Moreover, modern scientific research has unveiled the potential of mushrooms in biotechnology, pharmaceuticals, and environmental solutions. Their unique properties, including bioactive compounds and rapid growth, have led to discoveries ranging from antibiotic development to bioremediation of pollutants. In recent years, the growing interest in sustainable agriculture and the search for alternative protein sources has ignited a resurgence of interest in cultivating mushrooms as an environmentally friendly food option. As our understandingof mushrooms continues to expand, their multifaceted importance becomes increasingly evident.

[0005] Basidiomycete mycelia refer to the vegetative, filamentous, and often branching structures of fungi belonging to the phylum Basidiomycota. Basidiomycota is one of the major phyla of fungi and includes a wide range of fungi, some of which are well-known, such as mushrooms, puffballs, and bracket fungi. Mycelia are the mass of thin, thread-like structures called hyphae that make up the body of a fungus. These hyphae collectively form the mycelium, which is responsible for the fungus's growth and nutrient absorption. The mycelium plays a crucial role in the life cycle of basidiomycetes, as it is responsible for obtaining nutrients from the environment, breaking down organic matter, and sometimes forming mutualistic associations with plants.

[0006] In basidiomycetes, the mycelia are often found underground or within the substrate they are growing on. When conditions are favorable, such as when there is enough moisture and the temperature is adequate, basidiomycete mycelia can give rise to the reproductive structures known as basidiocarps. These basidiocarps can take various forms, such as mushrooms or shelf fungi, and they produce basidiospores, which are the spores responsible for the dispersal and reproduction of the fungus.

[0007] More recently, mycelium is being utilized as a material for consumer products, such as building materials, protective equipment, clothing and shoes, packaging materials, bioleather materials, office products, bioelectronics, bioremediation constructs, medical implants, and more. However, because traditional mycelium cultivation relies on solid growth substrates, the shapes and forms it can take are limited; therefore, the formation of wearables typically requires a cumbersome multi-step process including cultivating the mycelium, flattening it into sheets, and using the sheets to form the consumer products. The inventors of the present disclosure have endeavored to provide a more efficient and effective process for forming consumer products, including wearables, from mycelium.SUMMARY

[0008] The present disclosure describes systems and methods forming customized wearables directly through the cultivation of fungal mycelium. Particularly, according toone aspect of the disclosure, a method of forming a consumer product using a mycelium cultivation system can include forming a mold, casting a porous growth substrate from the mold, inducing mycelial growth on an exterior surface of the porous growth substrate to form a mycelial growth structure, and separating the mycelial growth structure from the porous growth substrate. In some aspects, the porous growth substrate can be formed of a ceramic material. In other aspects, casting the porous growth substrate from the mold can include forming the porous growth substate to include a central cavity. Further, inducing mycelial growth on the porous growth substrate can include inoculating the porous growth substrate with a mycelium inoculate and can further include operating a cultivation system. The cultivation system can include a liquid reservoir containing a liquid growth medium and a pump system, wherein the pump system can selectively transfer the liquid growth medium from the liquid reservoir to the porous growth substrate.

[0009] This summary is provided to introduce a selection of the concepts that are described in further detail in the detailed description and drawings contained herein. This summary is not intended to identify any primary or essential features of the claimed subject matter. Some or all of the described features may be present in the corresponding independent or dependent claims, but should not be construed to be a limitation unless expressly recited in a particular claim. Each embodiment described herein does not necessarily address every object described herein, and each embodiment does not necessarily include each feature described. Other forms, embodiments, objects, advantages, benefits, features, and aspects of the present disclosure will become apparent to one of skill in the art from the detailed description and drawings contained herein. Moreover, the various apparatuses and methods described in this summary section, as well as elsewhere in this application, can be expressed as a large number of different combinations and subcombinations. All such useful, novel, and inventive combinations and subcombinations are contemplated herein, it being recognized that the explicit expression of each of these combinations is unnecessary.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] While the specification concludes with claims which particularly point out and distinctly claim this technology, it is believed this technology will be better understoodfrom the following description of certain examples taken in conjunction with the accompanying drawings, in which like reference numerals identify the same elements and in which:

[0011] FIG. 1 depicts a schematic diagram of a mycelium cultivation system having an open-loop nutrient delivery system;

[0012] FIG. 2A depicts a cross-sectional view of the mycelium cultivation system of FIG. 1 taken along cutting plane 2A-2A, showing an internal filling material within the porous growth element;

[0013] FIG. 2B depicts a side perspective view of the mycelium cultivation system of FIG. 2A, shown with the pump system and tubing of the cultivation system removed;

[0014] FIG. 3 depicts a schematic diagram of a mycelium cultivation system having a closed-loop nutrient delivery system;

[0015] FIG. 4 depicts a front elevational view of one example application including a mycelium cultivation system, showing the porous growth element in an incubation stage of the mycelium growth process;

[0016] FIG. 5 depicts a front elevational view of one example application including a mycelium cultivation system, showing the porous growth element once the incubation stage of the mycelium growth process is complete;

[0017] FIG. 6 depicts a flowchart representation of one method of cultivating mycelium using a cultivation system;

[0018] FIG. 7 depicts a front elevational view of a plurality of experimental ceramic glove molds;

[0019] FIG. 8 depicts a front elevational view of one of the experimental ceramic glove molds of FIG. 7 during a mycelium cultivation experiment; and

[0020] FIG. 9 depicts a flowchart representation of one method of forming consumer products, including wearables, from mycelium.

[0021] The drawings are not intended to be limiting in any way, and it is contemplated that various embodiments of the technology may be carried out in a variety of other ways, including those not necessarily depicted in the drawings. The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present technology, and together with the description serve to explain the principles of the technology; it being understood, however, that this technology is not limited to the precise arrangements shown, or the precise experimental arrangements used to arrive at the various graphical results shown in the drawings.DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

[0022] The following description of certain examples of the technology should not be used to limit its scope. Other examples, features, aspects, embodiments, and advantages of the technology will become apparent to those skilled in the art from the following description, which is by way of illustration, one of the best modes contemplated for carrying out the technology. As will be realized, the technology described herein is capable of other different and obvious aspects, all without departing from the technology. Accordingly, the drawings and descriptions should be regarded as illustrative in nature and not restrictive.

[0023] It is further understood that any one or more of the teachings, expressions, embodiments, examples, etc. described herein may be combined with any one or more of the other teachings, expressions, embodiments, examples, etc. that are described herein. The following-described teachings, expressions, embodiments, examples, etc. should therefore not be viewed in isolation relative to each other. Various suitable ways in which the teachings herein may be combined will be readily apparent to those of ordinary skill in the art in view of the teachings herein. Such modifications and variations are intended to be included within the scope of the claims.

[0024] / . Exemplary Systems and Methods for Mycelium Cultivation Using Porous Materials

[0025] Modern industrial mushroom cultivation incorporates diverse techniques to meet global demand. Traditionally, mushroom growers have relied on complex substrates and meticulous control of environmental conditions to foster optimal mycelial growth. While these methods have been foundational to the mushroom industry, they present several challenges that hinder scalability and cost-effectiveness. The preparation and managementof solid substrates in traditional mushroom cultivation can be labor-intensive, timeconsuming, and resource demanding. Additionally, these processes may lead to inconsistencies in mycelial growth and overall yield.

[0026] More specifically, using solid substrates for mushroom cultivation presents a series of drawbacks that existing cultivators must navigate. Despite their effectiveness as growth mediums, solid substrates exhibit limitations that can impact cultivation outcomes. The confined surface area of solid substrates restricts the potential for robust mycelium colonization and mushroom formation, potentially leading to reduced yields. Uneven nutrient distribution within these substrates can result in unequal growth and hinder optimal mushroom development. The susceptibility to contamination by competing microorganisms and molds is heightened in solid substrates, posing challenges for maintaining sterile conditions. Additionally, the slower colonization rate necessitated by mycelium penetration extends cultivation times, elevating the risks associated with contamination and resource utilization. The significant quantities of raw materials required for solid substrates contribute to higher resource demands, while the disposal of spent substrate raises waste management concerns.

[0027] Additionally, the need for precise environmental controls further adds to the complexity of traditional cultivation practices. For example, bag cultivation involves sealed plastic bags filled with substrate contributing to plastic waste and low yields and could be labor-intensive for larger scales. Despite having some advantages, these techniques present challenges as well. Maintaining sterility is vital to prevent contamination that affects yields, and waste generation is a concern, particularly with single-use bags. Balancing efficiency, sustainability, and contamination control remains pivotal. Innovations that optimize resource use, minimize waste, and improve contamination management are needed to advance industrial mushroom cultivation sustainably.

[0028] Harvesting mushrooms from solid substrates can also prove labor-intensive, further complicating the cultivation process. As operations scale up, managing and sterilizing larger substrate volumes becomes intricate and resource intensive. Environmental considerations such as deforestation for wood-based substrates or resource intensive agricultural practices for substrates add to the complexity. Evaluating these drawbacksalongside the benefits is essential for cultivators to make informed decisions regarding solid substrate usage and explore alternative methods that align with their cultivation objectives.

[0029] Accordingly, the present disclosure provides an advantageous hydroponic mushroom growing system and method for providing nutrients to mycelium without using conventional solid substrate materials. The improved systems and methods militate against the resultant accumulation of contaminants, unwanted moisture, time-consuming preparation steps, growth space consumption, and the systems and methods better support mycelium for multiple flushes.

[0030] FIG. 1 shows a first example of a mycelium cultivation system (100). The system (100) includes various components such as a growth element (102), a fitting or coupling (104) configured to couple the growth element (102) to a tube (106), and a pump system (108). The pump system (108) may be a syringe pump, a peristaltic pump, or any other pump operable to store liquid in a reservoir contained therein and selectively deliver the liquid through the tube (106)) to the growth element (102).

[0031] In some embodiments, the growth element (102) includes a structure having pores (110). In particular embodiments described herein, the growth element (102) is formed of a porous ceramic material having an opening (112) that may accept the liquid from the reservoir. For instance, the opening (112) may include an open top section (112) for coupling with the fitting to receive liquid therefrom, a closed bottom section (1 14), and a main body (116) connecting the top section (112) with the bottom section (114). In some embodiments, the main body (116) is an elongated cylindrical shape, while it should be understood that the main body (116) and overall shape and size of the growth element (102) may take many forms while still performing the same functions as will be described herein. The growth element (102) may be formed to resemble a ceramic water filter, often referred to as a “ceramic filter candle,” defining an inner cavity (see, FIGS. 2A-2B) and a body surface having pores of around 0.2 microns to around 0.5 microns in diameter. A skilled artisan may select other suitable pore sizes, within the scope of the present disclosure. The pore size of the growth element (102) may be carefully selected (e.g., 0.2 microns) to retain any possible contaminant and deliver pure nutrient solution to the mycelial mass.Accordingly, processes involving bulk substrate sterilization at high temperatures is avoided, therefore leading energy and time savings.

[0032] In another embodiment, the porous growth element (102) can be made from an activated carbon, such as a natural coconut shell, or similar medium which could support the growth processes described herein.

[0033] One optional variation of the system (100) is to utilize the free space inside the porous growth element (102) by using activated carbon or organics such as wood shavings to induce a microbiome support or the living mycelium outside the tube or the generation of complex nutrients or to study the possible interaction of anaerobic microorganisms inside the tube with the growing mycelium in the surface. To that end, FIGS. 2A-2B show a cross-sectional view of the growth element (102), showing the contents positioned within the inner cavity. Specifically, an internal filling material (118) may be packed into the inner cavity. In some embodiments, the internal filling material (118) can include activated carbon granules, while in other embodiments the internal filling material (118) can include one or more other organic materials (or a combination thereof) such as wood shavings, straw, wheat bran, or any other organic materials which could support diverse microbes and facilitate symbiotic interactions between anaerobic microbes and the mycelium. The internal filling material (118) can further enhance mycelial growth by providing additional surface area and improved nutrient retention.

[0034] To cultivate mycelium growth using the system (100) of FIG. 1 , with reference to the method (300) shown in the flowchart of FIG. 6, the first step (203) involves preparing a liquid growth medium that provides essential nutrients for robust mycelium growth. The growth medium may include a combination of organic and inorganic compounds, vitamins, minerals, and other growth-promoting substances specific to the targeted basidiomycetes genus or type. In one non-limiting example, a peptone solution (e.g., 1.4 g), corn syrup (e.g., 20 g), yeast malt extract (e.g., 2 g), gypsum (e.g., 0.5 g), blue food coloring (e.g., 1 mL and water (e.g., 600 mL) may be combined. The composition of the growth medium can be adjusted to optimize the mycelial growth rate and productivity. The liquid growth medium is then introduced into a reservoir or container (see, pump system (108)) coupled with the growth element (102).

[0035] Additionally, at step (304), the organic materials can be placed into the growth clement, and at step (306) the growth element (102) is inoculated with a culture material (e.g., a liquid mycelium culture) to be cultivated and positioned within an environmentally controllable chamber. It should be understood that these steps may be carried out in reverse order. In some embodiments, the growth element (102) may instead be inoculated after the liquid growth medium is introduced into or onto the growth element (102) (see, step 308 below). The culture may contain one or more different mushroom species such as Shiitake, Oysters, Enokitake, Maitake, Lions Mane, Reishi, and / or Yeasts. Particularly, the liquid culture used can be a mixture of vegetative mycelium and a liquid nutrient solution.

[0036] Next, at step (308) the liquid growth medium previously prepared is pumped into and / or onto the growth element (102) via the tube (106). In some embodiments, the liquid growth medium is spread on the surface of the growth element (102) using any spreading means and the growth element (102) is placed inside a closed chamber (see, FIG. 4) to ensure isolation and protection from contaminants during incubation. Cultured growth elements (102) can be positioned in incubation tents at 25 °C in the dark for approximately three weeks. Further, at step (310) the liquid growth medium is carefully pushed or circulated through the growth element (102) through the inlet coupling (104) by means of the pump system (108), allowing it to come into contact with the outer surface of the growth element (102). As will be described below, in some embodiments the liquid growth medium may be re-circulated and reused at step (312). As the growth medium flows through the growth element (102) via the pores (110), the basidiomycetes mycelia attach and propagate on the surface of the growth element (102). The activated carbon (118) within the growth element (102) further supports mycelial development, fostering a healthy and robust growth pattern. In one example, the pump system (108), tube (106) and inlet coupling (104) are configured provide the liquid growth medium at a rate of around 125 pL per hour. As described above, the growth element (102) serves as the physical support system for the mycelium, replacing the need for conventional solid substrates.

[0037] Simultaneous to the liquid growth medium being circulated through the growth element (102), at step (314) the environmental conditions around the growth element (102) are meticulously monitored and, at step (316) adjusted as needed throughout the incubation process to optimize mycelium growth. Factors such as temperature, humidity, lightexposure, and air circulation are adjusted to suit the specific requirements of the targeted basidiomycctcs genus or type. By providing an ideal growth environment, the invention ensures consistent mycelial growth and minimizes the risk of contamination. In some embodiments, the mycelium is configured to incubate in a dark grow chamber at 20-30 °C. The above steps (308, 310, 312, 314, 316) are repeated at pre-determined intervals until, at step (318) the system or a user determines that the growth is complete.

[0038] Once growth is complete, in some embodiments, the additional step (320) of fruiting the mycelium may be initiated. In one example, gypsum may be added to the liquid media and the growth chamber set to 20-30 °C at 50 - 90% of relative humidity for fruiting. Additionally, fruiting may also include setting the growth chamber environment to provide 3 - 12 hours of darkness, followed by 21 - 12 hours of light, with constant airflow. Finally, at step (322), the mycelium and / or fruits may be harvested.

[0039] FIG. 3 shows a second example of a mycelium cultivation system (200). The system (200) includes similar components and functions as system (100), such as a growth element (202), a fitting or coupling (204) configured to couple the growth element (202) to a tube (206), and a pump system (208) (e.g., a syringe pump, a peristaltic pump, or any other pump operable to push liquid through the tube (206)) configured to supply liquid materials to the growth element (202) via the tube (206). Additionally, the lower end (210) of the growth element (202) includes an outlet coupling (212) coupled with an outlet tube (214). The outlet / outlet coupling (212) may be fluidly coupled to the liquid reservoir (216). The outlet tube (214) further couples with a liquid reservoir (216). Finally, the liquid reservoir (216) is fluidly coupled with the pump system (208) via another tube (218). As such, the system (200) provides an open inlet (204) and outlet (212) for liquid media to be recirculated from the growth element (202) to the reservoir (216) and back to the growth element (202) as necessary by selectively pumping the liquid through the tubes (206, 214, 218) via the pump system (208) see, step 312 of FIG. 6). In some embodiments, the growth element (202) can define an ellipsoidal base instead of the typical circular one (not shown), or it may define a spiral body form (not shown) to more effectively pass the liquid growth medium therethrough it toward the lower end (210).

[0040] The versatility of the porous tube method enables diverse mushroom species to be cultivated for food production, materials, or research purposes (e.g., basidiomycetes, yeast,molds etc.). The internal growth element composition and pore sizes allow anaerobic microbes to grow inside the growth element tubes and symbiotically interact with the external mycelium. Activated carbon housed within the growth element tubes provides supplemental nutrition and helps induce fruiting and mushroom formation. By avoiding energy -intensive sterilization of bulk substrates, the process is more sustainable. The liquid nutrients and surface area contact lead to more rapid, consistent mycelial growth kinetics. And the system reduces raw material waste compared to disposed solid mushroom substrates. Automated nutrient delivery provides precise moisture and nutritional control throughout cultivation. Lower risks of contamination improve overall yields compared to traditional practices. And the reusable growth element tubes and liquid systems are facile to clean for multiple growth cycles. The system also allows for different ceramic configurations depending on the growth requirements because elongated (ellipsoidal) growth element tubes, spiral growth element tubes, growth element tubes with bifurcations all increase the contact area for growth. The versatility of this technique enables multiple options of growth depending on the requirements of each species and final application.

[0041] In an embodiment where a plurality of systems (100 or 200) is utilized, multiple growth elements (102, 202) may be incubated simultaneously in a large container with multiple holders, and fructification may be induced on multiple growth elements (102, 202) simultaneously using a manifold.

[0042] FIG. 4 illustrates one example application of the above systems and methods. Particularly, shown in FIG. 4 is a growth element (1) positioned inside a chamber (2) and having a coupling (3) defining a liquid inlet (4) thereon. The chamber (4) shown is made of either polypropylene or glass. The porous ceramic tube growth element (1) is shown in the incubation state containing the growing mycelium, with the mycelium growing in the surface. The porous ceramic tube growth element (1) includes an inner cavity filled with activated carbon granules. As such, the growing mycelium corresponds to any basidiomycete, yeast, or mold. FIG. 5 shows the example system of FIG. 4, with the chamber removed and a pump system (4) coupled with the inlet (3). Specifically, the pump system (4) includes a syringe for introducing the liquid growth medium to the growth element (1). In FIG. 5, the porous growth element (1) illustrates the stage of the incubation process whereby the mycelium growth is complete. It should be understood that theillustrated instances and scenarios are merely indicative of the innovation, and all variations that align with the essence of the invention and fall within the scope of the appended claims are intended to be encompassed.

[0043] IL Exemplary Systems and Methods for Direct Cultivation of Mycelium-Based Consumer Products

[0044] The systems and methods described in the section above circumvent the need for solid substrates for mycelium cultivation in favor of circulating liquid nutrient solutions through porous structures for mycelium cultivation. These innovative techniques enable more consistent nutritional content and environmental conditions. However, these porous structures described above often produce irregular mycelial shapes and lack features to provide a user precise control of the growth morphology. As such, described below are techniques to cultivate mycelium directly into customized shapes, such as to efficiently “grow” consumer products. While the techniques would provide for virtually any shape of consumer goods to be grown, the illustrative examples shown and described herein focus on the formation and growth of gloves wearable on human hands for radiation blocking applications, such as for use in outer space.

[0045] Existing radiation blocking glove materials rely on heavy metals such as lead or proprietary polymer composites. However, these materials often lack flexibility, breathability, and comfort, which are critical properties for functional gloves wearable in outer space. Mycelium has shown to be an effective radiation blocking material. Particularly, previous research has observed radiation resistant fungi growing in the Chernobyl disaster site. Studies indicate certain fungi species can adapt to radiation through mechanisms like enhanced DNA repair. The melanin in mycelial cell walls can provide a degree of radiation shielding. However, there are no existing cultivation methods that leverage mycelium's innate radiation resistance for protective applications, and more particularly, there are no existing methods to cultivate mycelium into a tailored hand shape and directly into a final glove form.

[0046] Accordingly, the present disclosure provides systems and methods for fungal mycelium cultivation within customizable molds designed to achieve user-specified mycelial growth morphologies. Nutrient delivery means are integrated within the molds to precisely direct and promote mycelium formation throughout the mold surface. In oneembodiment, as shown in FTG. 7, a mold (400) is provided which takes the shape of the desired mycelium article, such as a radiation blocking glove. Once the mold (400) is inoculated with the mycelia, liquid nutrient lines (not shown) (see, for example, FIGS. 1 and 3) supply nutrients to the developing mycelium. The morphology is therefore controlled through nutrient modulation to achieve a dense mycelial structure matching the target shape provided by the mold (400).

[0047] Several materials may be utilized to create the molds, such as a hollow form, plaster, water, clay, and fibrous paper. In the particular embodiment described, the hollow form included a rubber dishwashing glove, the plaster included plaster of Paris, and the fibrous paper included toilet paper. The clay can further include a specialized combination of materials, clays, fluxes, silicas, and / or feldspars to ensure control of the results with temperature and surface porosity. For example, the clay in this particular embodiment includes soda ash, ball clay, Edgar Plastic Kaolin (EPK) Custer Feldspar, silica, and sodium silicate. In alternative embodiments, the soda ash and sodium silicate may be substituted with the commercial deflocculant Darvan 7. While various specific elements are listed, it should be understood that other materials may be included as well as this is not intended to be an exhaustive list.

[0048] FIG. 8 shows one mold (400) during a cultivation process using Reishi mushrooms. It should be understood that, while Reshi mushrooms were used in the experimental example, a wide variety of fungi could instead be cultivated using the described systems. Once cultivation is complete, the cultured mycelium is processed within the mold to transform it into a functional biomaterial-based consumer product, such as the radiation resistant “leather” gloves shown and described, without disturbing the achieved growth morphology. The final mycelium article is then ready for use one peeled away from the mold (400).

[0049] FIG. 9 shows a flowchart of one method (500) of forming consumer products, including wearables, from mycelium. At step (502), a reusable mold is formed of the article, such as from plaster or a similar material commonly used to form molds. Next, at step (504), a ceramic growth substrate is formed using the mold, the ceramic growth substrate taking the customized shape of the mold. In some embodiments, certain materials such as cellulose can be added to the clay to increase the hydraulic conductivity or porosityof the fired ceramic growth substrate. Tn other embodiments, additional or alternative modifications could be made to the clay to modify the ceramic substrate, such as adding grog (pre-fired and ground clay), sand, gravel, aggregates, perlite, vermiculite, organic matter, synthetic polymers, gypsum, lime, or biodegradable materials such as shredded paper or straw, among other materials. Next, at step (506), the method steps provided by method (300) may be carried out to cultivate the mycelium. Finally, at step (508), the cultivated mycelium may be processed (either on the ceramic substrate or once removed from the ceramic substrate) to form the final consumer article.

[0050] The systems and method described above promote transformation of cultured mycelium directly into tailored radiation blocking gloves or other consumer products. The ability to control the mycelium morphology during cultivation represents an important advancement in the art compared to current state-of-the-art mycelium cultivation practices.

[0051] Reference systems that may be used herein can refer generally to various directions (for example, upper, lower, forward and rearward), which are merely offered to assist the reader in understanding the various embodiments of the disclosure and are not to be interpreted as limiting. Other reference systems may be used to describe various embodiments, such as those where directions are referenced to the portions of the device, for example, toward or away from a particular element, or in relations to the structure generally (for example, inwardly or outwardly).

[0052] While examples, one or more representative embodiments and specific forms of the disclosure have been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive or limiting. The description of particular features in one embodiment does not imply that those particular features are necessarily limited to that one embodiment. Some or all of the features of one embodiment can be used in combination with some or all of the features of other embodiments as would be understood by one of ordinary skill in the art, whether or not explicitly described as such. One or more exemplary embodiments have been shown and described, and all changes and modifications that come within the spirit of the disclosure are desired to be protected.

Claims

CLAIMSI / we claim:

1. A method of forming a consumer product using a mycelium cultivation system, the method comprising:(a) forming a mold;(b) casting a porous growth substrate from the mold;(c) inducing mycelial growth on an exterior surface of the porous growth substrate to form a mycelial growth structure; and(d) separating the mycelial growth structure from the porous growth substrate.

2. The method of Claim 1, wherein the porous growth substrate is formed of a ceramic material.

3. The method of Claim 1, wherein casting the porous growth substrate from the mold includes forming the porous growth substate to include a central cavity.

4. The method of Claim 1, wherein inducing mycelial growth on the porous growth substrate includes inoculating the porous growth substrate with a mycelium inoculate.

5. The method of Claim 4, wherein inducing mycelial growth on the porous growth substrate includes operating a cultivation system, wherein the cultivation system includes a liquid reservoir containing a liquid growth medium, and a pump system, wherein the pump system selectively transfers the liquid growth medium from the liquid reservoir to the porous growth substrate.

6. The method of Claim 5, further comprising a step of transferring the liquid growth medium from the porous growth substrate to the liquid reservoir.

7. The method of Claim 1, further comprising a step of disposing the inoculated porous growth substrate within a closed container after the step of inducing mycelial growth on the exterior surface of the porous growth substrate but before the step of separating the mycelial growth structure from the porous growth substrate.

8. The method of Claim 3, wherein the porous growth substrate includes an activated carbon material.

9. The method of Claim 1, further comprising a step of adjusting one of a temperature, a humidity, a light exposure, and an air circulation of the mycelium cultivation system to optimize mycelium growth.

10. A mycelium cultivation system comprising: a growth element; a tube; a fitting that couples the growth element to the tube; and a pump system that selectively transfers a liquid from a reservoir through the tube to the growth element.

11. The system of Claim 10, wherein the growth element includes a porous ceramic material.

12. The system of Claim 1 1 , wherein the pores may have a diameter around 0.2 microns to around 0.5 microns in size.

13. The system of Claim 11, wherein the growth element includes an opening that accepts the liquid.

14. The system of Claiml l, wherein the porous growth element is constructed from an activated carbon material.

15. The system of Claim 10, wherein the pump system includes one of a syringe pump and a peristaltic pump.

16. The system of Claim 10, wherein the growth element includes a cavity, and an internal filling material is disposed within the cavity, the internal filling material includes an organic material that promotes mycelial growth.

17. The system of Claim 16, wherein the internal filling material includes an organic material.

18. The system of Claim 17, wherein the internal filling material includes activated carbon granules.

19. The system of Claim 13, wherein the growth element includes an outlet that is fluidly coupled to the reservoir.

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