Mycelium composite production method

Abstract

The present invention relates to the production of biocomposite materials through the co-cultivation of mycelium and algae. This innovative method integrates sustainable practices and utilizes waste materials to create carbon-negative, durable, and biodegradable composites suitable for various applications, including interior design, construction, automotive and packaging.

Description

[0001] Mycelium Composite Production Method

[0002] Field of the Invention

[0003] The present invention relates to the production of biocomposite materials through the cocultivation of mycelium and algae. This innovative method integrates sustainable practices and utilizes waste materials to create carbon-negative, durable, and biodegradable composites suitable for various applications, including interior design, construction, automotive and packaging. In particular, the invention is pertinent to a biotechnological production method that involves the use of the symbiotic relationship of the mycelium, which is the root system of fungi, and algae, from industrial and agricultural waste.

[0004] Background of the Invention

[0005] The growing environmental concerns associated with the use of conventional plastics and wood in composite materials have driven the need for sustainable alternatives. Mycelium, the vegetative part of fungi, has shown promise as a biodegradable and robust materialfor biocomposites. Algae, known for its rapid growth and oxygen production capabilities, can further enhance the properties of mycelium-based composites. The combination of mycelium and algae in a biocomposite material offers a unique solution to reduce reliance on non-renewable resources while improving the mechanical and functional properties of the resulting product.

[0006] A fully circular biotechnological production method is needed for biocomposites that do not contain any toxic materials in them, do not harm the consumer and the environment during their utilization, completely dissolve in the soil, rejoin the ecological cycle, and can even act as fertilizers.

[0007] The patent application W02020237201 A1 discusses mycelium materials and their production, featuring a composite mycelium material made from inoculated mycelium containing branching hyphae. US20120270302A1 describes a method for creating dehydrated mycelium elements by combining mycelium with fibers or particles, adding a nutrient source, and dehydrating the mixture. W02018014004A1 details a process for producingfungal materials by growing fungal tissue in a medium. WO2021245608A1 discloses a method for coating fungal mats with a bio-based composite material. US9485917B2 focuses on producing materials from inoculated hyphae and mycelium. US10537070B2 covers a roll-to- roll production method for mycelia composite surfaces. US9801345B2 reveals a self-sustaining composite material with interconnected mycelium cells. US10154627B2 outlines a method for growing mycological biomaterials. W02023 / 007194 discloses a process for preparing a biobased material based on bacteria and yeast (SCOBY). Lastly, this review discusses the latest advances on Material Function of Mycelium Based Bio-composite (Front. Mater., 30 September 2021 Sec. Biomaterials Volume 8 - 2021 | https: / / doi.org / 10.3389 / fmats.2021.737377)

[0008] These patents highlight the need for advancements in the field due to current challenges and limitations.

[0009] Summary of the Invention

[0010] The invention provides a method and system for producing biocomposite materials by cocultivating mycelium and algae. The process involves preparing a substrate from textile waste, inoculating it with mycelium, and co-cultivating it with algae in a controlled environment. The resulting biocomposite material is dehydrated, pressed under hydraulic pressure, and optionally coated with algae-derived bio-coatings to enhance its properties. The invention also encompasses specific combinations of mycelium and algae strains, growth conditions, and substrate compositions to optimize the performance of the biocomposite material. This innovative process utilizes sustainable practices and waste materials to create environmentally friendly, durable, and biodegradable composites suitable for various applications, including interior design.

[0011] In a first embodiment, the present invention related to a method to produce a biocomposite materials comprising mycelium and algae, characterized in that said biocomposite material is produced in a method, comprisingthe steps of:

[0012] - a. providing a substrate suitable for mycelium growth, wherein the substrate comprises 80 to 90% small particle size textile waste supplemented with 10 to 20% elongated textile fibers by weight;

[0013] - b. sterilizingor pasteurizingthe substrate; - c. inoculating the substrate with a mycelium strain in a 4:1 to 6:1 v / v ratio;

[0014] - d. providing a liquid culture medium suitable for algae growth, enriched with essential nutrients;

[0015] - e. inoculating the liquid culture medium with an algae strain;

[0016] - f. co-cultivating the mycelium and algae in a controlled environment such that the mycelium grows on the substrate and the algae grow in the liquid culture medium, maintaining a temperature range of 20 to 30°C and a humidity level of 80 to 90%;

[0017] - g. allowing the mycelium and algae to interact du ring the growth period of 5 days to 4 weeks, thereby forming a biocomposite material comprising mycelium and algal biomass, with the algae constituting©.5 to 30% by weight of the total biomass;

[0018] - h. dehydrating the biocomposite material at 40-70°C for 8 to 72 hours to reduce moisture content;

[0019] - i. pressingthe dehydrated mycelium-algae composite under a hydraulic press at a pressure of 1- 25 MPa to obtain a mycelium board;

[0020] - j. applying a bio-coating to the mycelium board to enhance its durability and functionality, wherein the bio-coating comprises 5-15% algal extracts or derivatives by weight; and

[0021] - k. drying and curing the molded biocomposite material at 40-70°C for 8-72 hours to enhance its structural integrity and durability.

[0022] In a further embodiment, the present invention relates to the usage of mycelium strains preferably selected from the group consisting of Pleurotus ostreatus, Ganoderma lucidum, Trametes versicolor, and Agrocybe cylindracea, and to the usage of algae strains preferably selected from the group consisting of Chlorella vulgaris, Scenedesmus vacuolatus, Nannochloropsis gaditana, Botryococcus braunii, Arthrospira platensis, Kirchneriella lunaris, and Laminaria spp. in a specific ratio.

[0023] In a further embodiment, the present invention relates to a biocomposite material, preferably a mycelium-algae biocomposite material, prepared using the described method.

[0024] In again a further embodiment, the present invention relates to a biocomposite material comprising a matrix of mycelium interspersed with algal biomass, providing enhanced mechanical properties, fire retardancy, impact resistance, biodegradability, and lightweight characteristics. In a further embodiment, the present invention relates to a biocomposite material that includes a bio-coating layer, enhancing the material’s durability, environmental resistance, and functional properties, such as UV protection and antimicrobial activity.

[0025] In a further embodiment, the present invention relates to the usage of biocomposite material in the production of mycelium-algae-based materials suitable for interior design elements, serving as an alternative to wood and plastic materials, and substituting for particle boards and plastic foams.

[0026] In again a further embodiment, the present invention relates to a system for producing biocomposite materials, comprising:

[0027] - a substrate preparation unit for preparing and sterilizing a substrate suitable for mycelium growth, including small particle size textile waste supplemented with elongated textile fibers;

[0028] - a mycelium inoculation unit for inoculating the substrate with a mycelium strain;

[0029] - a liquid culture preparation unit for preparing a liquid culture medium suitable for algae growth;

[0030] - an algae inoculation unit for inoculating the liquid culture medium with an algae strain;

[0031] - a co-cultivation chamber configured to maintain a controlled environment for the simultaneous growth of mycelium on the substrate and algae in the liquid culture medium;

[0032] - a dehydration unit for reducingthe moisture content of the biocomposite material;

[0033] - a hydraulic press for pressing the dehydrated mycelium-algae composite to obtain a mycelium board;

[0034] - a bio-coating application unit for applying a bio-coating comprising algal extracts or derivatives to the mycelium board, wherein sensors and monitoring systems track the growth of mycelium and algae, adjust environmental conditions accordingly, and preferably the volumetric ratio of algae culture to mycelium substrate is maintained within the range of 1 :5 to 4:1 (v / v).

[0035] Detailed Description of the Invention

[0036] The present invention will be described in the following. It is to be understood that all the combinations of features are envisaged. In a first embodiment, the present invention relates to a method and system for producing biocomposite materials through the co-cultivation of mycelium and algae, characterized in that said biocomposite material is produced in a method, comprisingthe steps of:

[0037] - a. providing a substrate suitable for mycelium growth, wherein the substrate comprises 80 to 90% small particle size textile waste supplemented with 10 to 20% elongated textile fibers by weight;

[0038] - b. sterilizingor pasteurizingthe substrate;

[0039] - c. inoculating the substrate with a mycelium strain in a 4:1 to 6:1 v / v ratio;

[0040] - d. providing a liquid culture medium suitable for algae growth, enriched with essential nutrients;

[0041] - e. inoculating the liquid culture medium with an algae strain;

[0042] - f. co-cultivating the mycelium and algae in a controlled environment such that the mycelium grows on the substrate and the algae grow in the liquid culture medium, maintaining a temperature range of 20 to 30°C and a humidity level of 80 to 90%;

[0043] - g. allowing the mycelium and algae to interact du ring the growth period of 5 days to 4 weeks, thereby forming a biocomposite material comprising mycelium and algal biomass, with the algae constituting©.5 to 30% by weight of the total biomass;

[0044] - h. dehydrating the biocomposite material at 40-70°C for 12 to 72 hours to reduce moisture content;

[0045] - i. pressingthe dehydrated mycelium-algae composite under a hydraulic press at a pressure of 1- 25 MPa to obtain a mycelium board;

[0046] - j. applying a bio-coating to the mycelium board to enhance its durability and functionality, wherein the bio-coating comprises 5-15% algal extracts or derivatives by weight; and

[0047] - k. drying and curing the molded biocomposite material at 40-70°C for 8-72 hours to enhance its structural integrity and durability.

[0048] The method begins with the preparation of a substrate suitable for mycelium growth. This substrate comprises 80 to 90% small particle size textile waste, supplemented with 10 to 20% elongated textile fibers by weight. The substrate is then sterilized or pasteurized to eliminate any contaminants. To further enhance mycelium growth, the substrate is supplemented with 1 to 20%, preferably with 5 to 10% by weight of a mixture preferably selected from cotton, algal biomass, hemp, oat, rice, millet, rye, wood waste, sawdust, wood shavings, straw, tea, coffee, brewery wastes, bacterial cellulose, paper sludge, marble powder, calcite, pearlite, vermiculite, or regolith. Following the co-cultivation process, the biocomposite material undergoes a dehydration step in a laboratory oven or drying chamber at 40 to 70 °C for a duration ranging from 8 to 72 hours, dependingon the sample thickness, substrate composition, and humidity conditions.

[0049] This dehydration process is designed to gradually evaporate residual moisture from within the material matrix without compromising its internal structure. Controlled drying at moderate temperatures prevents thermal degradation of fungal and algal components while promoting uniform shrinkage.

[0050] The goal is to reduce the overall moisture content of the material to less than 30%, preferably below 20%, and most preferably under 10%, thereby enhancing the mechanical stability, shelf life, and resistance to microbial degradation. Dehydration also prepares the biocomposite for subsequent post-processing steps such as hydraulic pressing and bio-coating application.

[0051] Optionally, the dehydrated mycelium-algae biocomposite is subjected to compression using a hydraulic or hot press system, preferably at a pressure of 1 to 30 MPa more preferably at a pressure of 1 to 25 MPa to form a mycelium board. For enhanced mechanical performance and densification, the pressing may be conducted under elevated temperatures ranging from 80 °C to 130 °C for a duration of 5 to 50 minutes, depending on the thickness and composition of the composite. This step increases the composite’s structural cohesion, surface uniformity, and water resistance.

[0052] The small particle size textile waste refers to shredded textile fragments having an average particle diameter of approximately 0.3 cm, preferably ranging between 0.1 cm and 0.5 cm. The particle size is optimized to ensure sufficient mycelium penetration and homogeneous substrate colonization.

[0053] The small particle size textile waste used in the substrate is primarily sourced from post-production offcuts generated during textile manufacturing processes. These industrial textile remnants are typically pre-cut and fall within the desired particle size range of 0.1 to 0.5 cm, with an optimal average of approximately 0.3 cm, requiring no further processing.

[0054] In cases where the supplied textile waste exceeds the target particle size, it is subjected to mechanical shredding using hammer mills or knife mills to ensure a homogeneous and myceliumcompatible substrate. The shredded material is then classified using sieving with mesh sizes correspondingto the target particle size range.

[0055] The textile composition is preferably based on cellulose-rich fibers, such as cotton, and may also include viscose, hemp, wool or blends with synthetic materials like polyester. This composition is chosen for its biodegradability, nutrient availability, and structural compatibility with fungal growth, enabling consistent substrate colonization and reproducible biocomposite formation. Preferably, the textile waste used as substrate is predominantly composed of post-industrial cotton-rich blends comprising at least 60% of cotton by weight, and optionally comprising other substrates selected from polyester, wool, viscose and hemp. The mycelial colonization was observed to be consistent within these fiber compositions. Waste types containing more than 50% synthetic polymer content were excluded or pre-treated, as they inhibited fungal growth.

[0056] The elongated textile fibers refer to fibrous elements derived predominantly from cotton, but also including polyester, viscose, hemp, and wool blends. These fibers are typically integrated into the substrate in mesh-like or interwoven arrangements, forming a reinforcement network within the biocomposite matrix. The individual fiber segments are cut to lengths slightly shorter than the final dimensions of the target panel (typically 0.5-1 cm less in both width and height) to allow internal placement without edge protrusion and to maintain a uniform outer surface. This configuration provides structural anchoring for the growing mycelium, improving panel strength, dimensional stability, and resistance to delamination.The composite panel, as defined herein, refers to the final mycelium composite material formed through the co-cultivation process, comprising the mycelium matrix interspersed with algal biomass and reinforced with textile fibers.

[0057] Preferably, the elongated textile fibers have specific dimensional characteristics including fiber diameters ranging from 10-50 micrometers and length-to-width ratios of 100:1 to 10000:1 for optimal reinforcement properties. The fibers exhibit crimp characteristics that enhance interlocking within the mycelium matrix In other words, this enhances the structural strength of the biocomposite material by a range of 10 to 40%. The structural strength is herein understood by tensile strength.

[0058] Preferably, the mechanical properties of the elongated textile fibers include tensile strength values ranging from 200-800 MPa for different fiber types, elastic modulus ranges of 5-70 GPa, and elongation at break percentages of 2-40% depending on the fiber composition. These properties contribute to fatigue resistance characteristics of the final biocomposite.

[0059] The fibers are arranged in specific mesh patterns including woven, non-woven, or random configurations with fiber orientation angles optimized for directional strength. Multi-directional reinforcement is achieved through layering sequences, with fiber volume fractions typically ranging from 1- 30%, more preferably 1-10% in the final composite.

[0060] The fiber inclusion enhances mechanical strength and shape stability of the resulting biocomposite. The elongated textile fibers provide directional strength and prevent cracking during the dehydration and pressing processes, contributing to the overall structural integrity of the final biocomposite material through effective mycelium-fiber bonding mechanisms and load transfer efficiency between the matrix and reinforcing fibers.

[0061] In one embodiment, the substrate, comprising textile fibers and nutritional supplements is subjected to sterilization to eliminate microbial contaminants. Sterilization is achieved via thermal treatment, wherein the substrate is exposed to a temperature range of 100°C to 130°C for a duration sufficient to ensure aseptic conditions, preferably between 20 to 60 minutes. The process may be conducted using an autoclave, steam chamber, or equivalent pressure-based sterilization unit, ensuring homogenous heat distribution throughout the substrate mass.

[0062] Preferably, the mycelium strains are selected from basidiomycota.

[0063] Preferably, the mycelium strains are selected from Pleurotus ostreatus, Ganoderma lucidum, Trametes versicolor, Fomes Fomentarius, and Agrocybe cylindracea. More preferably, the mycelium strains are selected from Pleurotus ostreatus, Ganoderma lucidum, Trametes versicolor, and Agrocybe cylindracea.

[0064] It is to be noted that non-filamentous fungi are excluded from the scope of the invention.

[0065] Concurrently, a liquid culture medium enriched with essential nutrients is prepared for algae growth and inoculated with an algae strain.

[0066] The algal species applicable within the scope of the invention are categorized into two functional groups based on their biological class and mode of integration. Preferably, the algal species applicable within the scope of the invention are selected from microalgae and macroalgae.

[0067] It is underwood that microalgae (e.g., Chlorella, Scenedesmus, Nannochloropsis, Kirchneriella, Botryococcus, Arthrospira, Staurastrum) are used in co-cultivation with fungal mycelium in liquid media (e.g., BG-11), enabling gas-phase interaction to boost fungal growth, biomass, and surface coverage. They may also be dried and added as nutrient supplements or bio-coating agents. Non- photoautotrophic strains are excluded.

[0068] It is understood that macroalgae (e.g., Laminaria, Gracilaria, Ulva) are multicellular seaweed species which are used in co-cultivation but preferably utilized in processed or extracted form as part of bio-coating formulations. Their derivatives, such as alginates (from Laminaria), carrageenan (from Gracilaria), and ulvans (from Ulva), are applied to the surface of the dried mycelium-algae composite panels to enhance water resistance, UV protection, and antimicrobial properties. These polysaccharides form semi-permeable surface films that improve structural durability and environmental resilience. They may also be dried and added as nutrient supplements.

[0069] Preferably, the algae strains are selected from Chlorella vulgaris, Chlorella variabilis, Chlorella pyrenoidosa, Kirchneriella lunaris, Staurastrum spp., Scenedesmus vacuolatus, Nannochloropsis gaditana, Botryococcus braunii, Arthrospira platensis, Laminaria spp., Gracilaria spp., and Ulva spp.

[0070] More preferably the algae strains are selected from Chlorella vulgaris, Scenedesmus vacuolatus, Nannochloropsis gaditana, Botryococcus braunii, Arthrospira platensis, Kirchneriella lunaris, and Laminaria spp.

[0071] Even more preferably, the algae strains are selected from Scenedesmus vacuolatus, Nannochloropsis gaditana, Arthrospira platensis, and Kirchneriella lunaris.

[0072] In one embodiment, the mycelium strain selected from Pleurotus ostreatus or Ganoderma lucidum orTrametes versicolor, is preferably combined with at least one of the algae strains selected from Chlorella vulgaris, Chlorella variabilis, Chlorella pyrenoidosa, Kirchneriella lunaris, Staurastrum spp., Scenedesmus vacuolatus, Nannochloropsis gaditana, Botryococcus braunii, Arthrospira platensis, Laminaria spp., Gracilaria spp., and Ulva spp., more preferably combined with at least one of the algae strains selected from Chlorella vulgaris, Scenedesmus vacuolatus, Nannochloropsis gaditana, Botryococcus braunii, Arthrospira platensis, Kirchneriella lunaris, and Laminaria spp., more preferably combined with at least one of the algae strains selected from Scenedesmus vacuolatus, Nannochloropsis gaditana, Arthrospira platensis, and Kirchneriella lunaris.

[0073] In another embodiment, the mycelium strain selected from Agrocybe cylindracea is preferably combined with at least one of the algae strains selected from Chlorella vulgaris, Chlorella variabilis, Chlorella pyrenoidosa, Kirchneriella lunaris, Staurastrum spp., Scenedesmus vacuolatus, Nannochloropsis gaditana, Botryococcus braunii, Arthrospira platensis, Laminaria spp., Gracilaria spp., and Ulva spp., more preferably combined with at least one of the algae strains selected from Chlorella vulgaris, Scenedesmus vacuolatus, Nannochloropsis gaditana, Botryococcus braunii, Arthrospira platensis, Kirchneriella lunaris, and Laminaria spp.

[0074] In an alternative embodiment, at least one of the mycelium strains selected from Pleurotus ostreatus, Ganoderma lucidum, Trametes versicolor, and Agrocybe cylindracea are combined with at least one of the algae strains selected from Chlorella vulgaris, Chlorella variabilis, Chlorella pyrenoidosa, Kirchneriella lunaris, Staurastrum spp., Scenedesmus vacuolatus, Nannochloropsis gaditana, Botryococcus braunii, Arthrospira platensis, Laminaria spp., Gracilaria spp., and Ulva spp., more preferably two of the mycelium strains selected from Pleurotus ostreatus, Ganoderma lucidum, Trametes versicolor, and Agrocybe cylindracea are combined with Chlorella vulgaris, Scenedesmus vacuolatus, Nannochloropsis gaditana, Botryococcus braunii, Arthrospira platensis, Kirchneriella lunaris, and Laminaria spp.

[0075] The sterilized substrate is preferably inoculated with a mycelium strain in a 4:1 to 6:1 v / v ratio, with a preferred ratio of 6:1 v / v, more preferably with a ratio of 5:1 v / v, most preferably with a ratio of 4:1 v / v. It is understood that this ratio is the ratio of the substrate to the mycelium strain.

[0076] Preferably, the growth is monitored and adjusted using sensors to maintain optimal growth conditions for both mycelium and algae.

[0077] The co-cultivation process is conducted in a controlled environment with a temperature range of 20 to 30°C and a humidity level of 80 to 90%. During this period, the mycelium grows on the substrate (solid-state) while the algae grow in the liquid culture medium (liquid state), interacting over a growth period of 5 days to 4 weeks through gas exchange (i.e. the produced 02 from algal growth is consumed for the mycelium growth, while the algal growth consumes the CO2 from mycelium growth).

[0078] Preferably, the algae biomass constitutes 0.5 to 50%, more preferably 0.5 to 10% by weight in the biocomposite material.

[0079] In one embodiment of the present invention, followingthe growth phase, the biocomposite material is dehydrated at 40 to 70°C for 8 to 72 hours to reduce its moisture content to less than 30%, more preferably to less than 20%, even more preferably to less than 10%, thereby enhancing its durability and structural integrity. The dehydrated mycelium biocomposite is optionally pressed under a hydraulic press at a pressure of 1 to 30 MPa, more preferably at a pressure of 1 to 25 MPa to form a mycelium board.

[0080] To further enhance biocomposite properties, a bio-coating comprising preferably 1 to 35% algal extracts or derivatives (algae-derived bioactive compounds) by weight, more preferably 5 to 20%, even more preferably 5 to 15% algal extracts or derivatives by weight, is applied to the mycelium biocomposite.

[0081] In one embodiment, the bio-coating in step j further includes integrating algae-derived bioactive compounds to improve the biocomposite's environmental resilience and functionality. It is understood that algae-derived bioactive compounds preferably comprise of at least one algal polysaccharide, algal lipids, algal proteins, and algal pigments, hence providing UV protection, water resistance, and antimicrobial properties.

[0082] It is understood that the bio-coating comprising algal extracts or derivatives (algae-derived bioactive compounds) refers to a specialized coating formulation prepared from algal biomass obtained during the co-cultivation process. Following the co-cultivation of mycelium and algae, the resulting algal culture is harvested and dried under controlled conditions to obtain algal biomass. This biomass is then divided into two portions: one is reintegrated into the mycelium substrate for subsequent composite growth, while the other is formulated into a bio-coating solution.

[0083] The algae-based bio-coating is prepared by suspending the dried biomass in an aqueous or hydroalcoholic solution containing a natural biopolymer binder, such as sodium alginate or agar. Optionally, hydrophobic additives (e.g., plant oils or wax emulsions) may be incorporated to improve water resistance. The algal biomass used in this formulation is preferably derived from strains such as Chlorella vulgaris, Scenedesmus vacuolatus, Nannochloropsis gaditana, Botryococcus braunii, Arthrospira platensis, Kirchneriella lunaris, and Laminaria spp., selected for their high content of functional biocompounds including polysaccharides, pigments, and lipids.

[0084] Alternatively, the bio-coating may comprise dried algal biomass directly applied without extraction or isolation of derivatives. In this embodiment, the harvested algal culture is dried under controlled conditions at temperatures ranging from 40-70°C for 8-24 hours to obtain a fine algal powder. This dried algal biomass is then directly incorporated into a coating formulation by mixing it with a minimal amount of natural binder solution, such as diluted sodium alginate or agar solution (0.5- 2% concentration), to form a paste-like consistency. The direct application method preserves the complete spectrum of algal bioactive compounds within their natural cellular matrix, potentially providing enhanced bioactivity compared to extracted derivatives. This approach is particularly advantageous for maintaining the structural integrity of heat-sensitive compounds and reducing processing costs while still delivering the desired functional properties including UV protection, antimicrobial activity, and water resistance.

[0085] The prepared coating formulation is applied to the surface of the dehydrated mycelium biocomposite using methods such as spray coating, brushing, or dip-coating, depending on the desired thickness and surface finish. The coating layer is typically applied in a thickness of 0.1 mm to 0.5 mm and subsequently dried and cured at 40-70°C for 12-72 hours.

[0086] The algae-based bio-coating provides enhanced UV resistance, moisture barrier properties, and antimicrobial activity, owing to the presence of chlorophylls, carotenoids, and phycobiliproteins in the algal biomass. Moreover, when formulated using algal species such as Botryococcus braunii or Laminaria spp., the coating may exhibit fire-retardant effects due to their intrinsic mineral or hydrocarbon content.

[0087] It is understood that algal extracts or derivatives, as used in the bio-coating of step j, refer to compounds obtained from algal biomass harvested during the co-cultivation process. Algal extracts comprise the dried algal biomass obtained by harvesting and drying the algal culture under controlled conditions. Algal derivatives include processed bioactive compounds extracted or isolated from the algal biomass, such as polysaccharides (including agar and carrageenan), pigments (includingchlorophylls, carotenoids, and phycobiliproteins), lipids (including omega-3 fatty acids), and proteins (including phycobiliproteins). These extracts and derivatives are formulated into a bio-coating solution by suspending the dried biomass in an aqueous or hydroalcoholic solution containing natural biopolymer binders such as sodium alginate or agar, optionally incorporating hydrophobic additives such as plant oils or wax emulsions to improve water resistance.

[0088] It is understood that algal polysaccharides are complex carbohydrates found in algae. Examples include agar and carrageenan, which are extracted from red algae and widely used as gelling agents in the food industry.

[0089] It is understood that algal lipids are fats and oils produced by algae. Examples include omega-3 fatty acids, such as eicosapentaenoic acid (EPA) and docosahexaenoic acid (DHA), which are found in microalgae like Nannochloropsis and Schizochytrium.

[0090] It is understood that algal proteins are proteins derived from algae, known for their high nutritional value and potential as sustainable food sources. Examples include phycobiliproteins, which are light-harvesting proteins found in cyanobacteria and red algae, and spirulina, a protein-rich biomass derived from Arthrospira platensis.

[0091] It is understood that algal pigments are natural compounds responsible for the coloration in algae, playing key roles in photosynthesis by capturing light energy. Examples include chlorophyll, which gives green algae their color, and fucoxanthin, a brown pigment found in brown algae like Laminaria and Phaeodactylum tricornutum.

[0092] It is understood that a mycelium-algae biocomposite is a mycelium biocomposite. In one embodiment of the present invention, the biocomposite material, further comprises added elongated textile waste and textile fibers, added in step a, preferably comprising of cotton or polyester or hemp or a combination thereof, more preferably comprising of cotton or polyester or a combination thereof, that preferably enhance the structural strength of the biocomposite material by a range of 15 to 45%, more preferably by a range of 30 to 40%.

[0093] The molded biocomposite material is subsequently dried and cured at 40 to 70°C for 8 to 72 hours to further enhance its structural integrity and durability. The technical advantages of this method include enhanced tensile strength and durability due to the incorporation of elongated textile fibers and the algal-based biocoating. Moreover, the process reduces reliance on non-renewable resources and offers environmental benefits from the oxygen production of algae during cocultivation.

[0094] In one embodiment, the biocomposite comprises a mycelium matrix with algal biomass uniformly integrated within the substrate. This configuration enhances mechanical strength and fire retardancy by promoting char formation. The presence of algal polysaccharides contributes to improved dimensional stability by minimizing shrinkage during drying and reduces water absorption due to their hygroscopic nature. The embedded algae also provide internal nutrients that support dense and uniform mycelial colonization.

[0095] In a further embodiment, the biocomposite includes a surface-applied algae-based bio-coating. This layer improves surface hardness, tensile strength, UV resistance, and antimicrobial activity. The coating acts as a semi-permeable barrier that limits moisture penetration, enhances durability against environmental factors, and extends the service life of the material under indoor and semiexposed conditions.

[0096] In one embodiment, the biocomposite material (comprising textile fibers) without surface treatment exhibits tensile strength values in the range of 0.4 to 2.9 MPa, preferably 0.4 to 1.2 MPa, more preferably 0.6 to 1 .0 MPa. When the bio-coating comprising algal extracts or derivatives is applied according to step j of the method, the tensile strength increases to between 0.5 to 4.5 MPa, preferably 0.7 and 1 .8 MPa, more preferably between 0.9 and 1 .5 MPa, thereby demonstrating enhanced mechanical integrity of the biocomposite material.

[0097] In an alternative embodiment, when the bio-coating comprises dried algal biomass directly applied without extraction, the biocomposite material (comprising textile fibers) exhibits tensile strength values rangingfrom 0.5 to 3.5 MPa, preferably 0.6 to 1 .6 MPa, more preferably from 0.8 to 1 .4 MPa, confirming the effectiveness of both coating methodologies disclosed herein.

[0098] In one embodiment, the biocomposite material obtained according to the method of this invention is bio-degradable. It is to be understood that the biocomposite comprising 100% natural textile fibers, renders the composite fully biodegradable; alternatively, if synthetic fibers are incorporated, biodegradability is reduced proportionally depending on the type, proportion, and processing of the synthetic material. In a further embodiment, the present invention relates to a system for producing biocomposite materials, comprising:

[0099] - a substrate preparation unit for preparing and sterilizing a substrate suitable for mycelium growth, including small particle size textile waste supplemented with elongated textile fibers;

[0100] - a mycelium inoculation unit for inoculating the substrate with a mycelium strain;

[0101] - a liquid culture preparation unit for preparing a liquid culture medium suitable for algae growth;

[0102] - an algae inoculation unit for inoculating the liquid culture medium with an algae strain;

[0103] - a co-cultivation chamber configured to maintain a controlled environment for the simultaneous growth of mycelium on the substrate and algae in the liquid culture medium;

[0104] - a dehydration unit for reducingthe moisture content of the biocomposite material;

[0105] - a hydraulic press for pressing the dehydrated mycelium-algae composite to obtain a mycelium board;

[0106] - a bio-coating application unit for applying a bio-coating comprising algal extracts or derivatives to the mycelium board, wherein sensors and monitoring systems track the growth of mycelium and algae, adjust environmental conditions accordingly, and preferably the volumetric ratio of algae culture to mycelium substrate is maintained within the range of 1 :5 to 4:1 (v / v), more preferably 1 :3 to 2:1 . The interaction ratio ensures enough gas exchange between algae and mycelium. In otherwords, the interaction ratio represents the ratio between mycelium biomass and the algae biomass in the co-cultivation that needs to be present so that enough co2 and o2 is exchanged.

[0107] In a further embodiment related to the system, the co-cultivation chamber is equipped with temperature and humidity control systems to maintain optimal growth conditions for both mycelium and algae, ensuring consistent and high-quality biocomposite production, and wherein the substrate preparation unit is capable of supplementing the substrate with 5-10% by weight of mixture selected from cotton, synthetic textile fibers, textile waste, algal biomass, hemp, oat, rice, millet, rye, wood waste, sawdust, wood shavings, straw, tea, coffee, brewery wastes, bacterial cellulose, paper sludge, marble powder, calcite, pearlite, vermiculite, regolith, to enhance mycelium growth, optimizing nutrient availability.

[0108] The co-cultivation chamber maintains environmental parameters within precise ranges: temperature control systems capable of maintaining 20-30°C with ±1 °C accuracy, humidity control systems maintaining 80-90% relative humidity with ±2% accuracy, and air circulation systems providing gentle airflow without disrupting mycelium growth. The chamber includes separate, light- isolated compartments for solid-state mycelium cultivation (kept in darkness) and liquid-state algae culture (exposed to controlled illumination). The lighting system comprises wavelength-specific LED arrays optimized for algal photosynthesis, delivering continuous or pulsed light within the 400-700 nm range. The algae compartment is equipped with a shaking platform to enable homogeneous mixing and improve gas-liquid mass transfer. Gas exchange systems facilitate oxygen and carbon dioxide transfer between compartments without cross-contamination. HEPA-filtered air inlets ensure sterile airflow, minimizing the risk of microbial contamination within the chamber.

[0109] Monitoring systems include temperature sensors, humidity sensors, pH meters for algal culture, dissolved oxygen sensors, and optical density measurement systems fortracking algal growth. An automated control unit dynamically adjusts environmental conditions based on real-time sensor feedback, ensuring optimal and compartment-specific growth conditions throughout the cocultivation process.

[0110] In the present invention, the growth medium is preferably potato dextrose agar (PDA) or malt extract agar (MEA). Potato dextrose agar and potato dextrose broth are common microbiological growth media made from potato infusion and dextrose. PDA is used as a selective solid medium for yeasts and molds. The carbohydrate and potato infusion in the composition support the growth of yeast and mold, while the low pH suppresses the bacterial growth. Malt extract agar is an agar medium used for the growth and isolation of yeast and molds. In addition, the development of test strains in vitamin analysis by microbial methods is also used.

[0111] Production method, which is subject of the invention, is explained as follows; In the first instance, industrial waste, which are the necessary raw materials for growing biocomposites, are selected by being classified according to their content in suitable proportions and components. The mentioned wastes are sterilized in the autoclave. Subsequently, the fungal species appropriate for the performance requirement of the biomaterial to be grown are selected among the Pleurotus ostreatus, Trametes versicolor, Ganoderma lucidum, and Agrocybe cylindracea species. Preferably PDA (Potato dextrose agar) or MEA (Malt Extract Agar) is prepared as a medium to produce mycelium from selected fungal species. Fungi which are inoculated in the medium are kept in a sterile environment or incubator in the dark and at room temperature for mycelium growth. Here, the growing mycelium is transferred to a new medium and sterile mycelium growth is ensured under appropriate environmental conditions for secondary inoculation. The growing mycelium is transferred to the mentioned sterilized substrates for multiplication. Here, the inoculated mycelium combined with the substrate is inoculated in the co-cultivation chamber. It is understood that a co-cultivation chamber is a specialized and controlled environment designed to facilitate the simultaneous growth and interaction of mycelium and algae, optimizing conditions for both organisms to form a cohesive biocomposite material. This chamber maintains precise control over environmental parameters such as temperature, humidity, light, and air quality to ensure optimal growth. It includes separate sections for solid-state mycelium cultivation and liquid-state algae culture, with systems to promote interaction between the two. The chamber is equipped with sensors and automated controls to monitor and adjust conditions in real-time, providing an ideal setting for the integrated development of biocomposite materials.

[0112] Various ratios of mycelium to substrate and algae to liquid culture medium were tested to identify the optimal conditions for producing high-quality biocomposite materials. Through extensive experimentation, it was determined that a substrate-to-mycelium inoculation ratio of 4:1 v / v, combined with an algae integration ratio constituting 20% by weight of the total biomass, yielded the best results. This specific combination demonstrated superior mechanical properties, including enhanced tensile strength and elasticity, which are critical for structural applications. Additionally, the selected ratio exhibited improved environmental resilience, such as better UV resistance and water repellency, attributed to the higher concentration of algae-derived bioactive compounds. Notably, this ratio also showed a faster growth rate compared to the separate cultivation of mycelium or algae alone, resulting in increased total biomass. Furthermore, it increased fire retardancy and reduced smoke release of the biocomposite material, enhancing its safety profile for interior design applications. Additionally, other process parameters were varied and optimized as well. These findings highlight the efficacy of the chosen ratios in producing a biocomposite material with optimal performance characteristics for use in the material industry, specifically in interior design elements as an alternative to traditional wood and plastic materials.

[0113] The invention is illustrated by the following example, which however is not to be construed as limiting.

[0114] Example 1

[0115] An example of the production of a mycelium-algae biocomposite material involves the preparation of a substrate comprising 85% small particle size textile waste (cotton) and 15% elongated textile fibers (polyester). The substrate was supplemented with 7% sawdust by weight and inoculated with the Pleurotus ostreatus mycelium strain and Chlorella vulgaris algae strain. The inoculated mycelium substrate was combined with the sterilized biocomposite substrate in a 4:1 v / v ratio (substrate:mycelium). Co-cultivation occurs at a temperature of 22°C and a humidity level of 85% over a 2-week period, resulting in a biocomposite material with 20% algae biomass by weight. Dehydration was conducted at 50°C for 18 hours, followed by pressing under a hydraulic press at 15 MPa. The final product was coated with algal extracts as a bio-coating, enhancing its properties like durability 10-30%, environmental resistance, and functional properties, such as UV protection and antimicrobial activity.

[0116] The biocomposite material produced by this method is suitable for use in interior design elements, serving as an alternative to wood and plastic materials. It can be used as a substitution for particle boards and plastic foams, providing a sustainable, durable, lightweight and fire-retardant solution. Example 2

[0117] Co-cultivation experiments

[0118] 1. Fungal Culture Preparation

[0119] The fungal strain used for co-cultivation was Trametes versicolor. Initial inoculation was performed on PDA plates until sufficient colonization occurred. Colonies were then transferred into a liquid culture medium for biomass expansion. As an alternative protocol, the fungus was also directly inoculated into petri dishes containing the substrate mixture.

[0120] 2. Algal Culture Preparation and Scaling

[0121] Chlorella vulgaris was selected for the algal component. An initial 50 mL algal culture was scaled up to 500 mL using distilled water and 0.5 g of BG-11 medium powder. The BG-11 solution was sterilized by autoclaving at 121 °C for 20 minutes. After cooling, the algal culture was introduced into the medium at a 10-20% inoculum-to-media ratio. Cultures were maintained in DURAN® Erlenmeyer flasks (500 mL) sealed with GL45 ventilation screw caps containing ePTFE membranes.

[0122] 3. Substrate Sterilization and Inoculation

[0123] The base growth substrate was cotton. This base was supplemented with nutritional additives as described in the specification. The prepared substrate was sterilized via autoclaving at 121 °C for 20 minutes under 1 atm overpressure. Once cooled, fungal culture was mixed into the substrate at the following volume-to-volume (v / v) ratios: 1 :2, 1 :4, 1 :6, and 1 :8. Substrates were placed in 9 cm petri dishes for incubation in a dark climate chamber at 26°C and %90 relative humidity.

[0124] 4. Incubation Conditions

[0125] The algal cultures were incubated in a shaking incubator set to 27°C at 144 rpm for 2 days. Algal cultures continued under shaking incubation with continuous illumination from PAR LED lamps providing 100 pmol / m2 / s light intensity, 20 cm distance to cultures, for 12 hours per day.

[0126] After the lag phase, 150 mL of algal culture was transferred into each of three separate 250 mL Erlenmeyer flasks. One flask was sealed with a GL45 ventilation cap. The remaining two were sealed with screwcaps fitted with hose connectors and connected to 0.22 pm gas filters and silicone tubing. Silicone tubes from the algal flasks were connected to the corresponding fungal petri dishes with 0.22 pm gas filters.

[0127] 5. Co-Cultivation Assembly

[0128] A- Algae-only culture (i.e. Chlorella vulgaris) in liquid state

[0129] B - Mycelium-only control (i.e. Trametes versicolor) in solid state

[0130] C - Mycelium & Algae co-cultivation (j.e.Chlorella vulgaris and Trametes versicolor, i.e. A+B connected via gas exchange)

[0131] D - (Mycelium + Algal biomass in solid state) & Algae co-cultivation

[0132] E - Mycelium + Algal biomass in solid state Results

[0133] Substrate Ratio

[0134] Four different mycelium-to-substrate volumetric ratios 1 :2, 1 :4, 1 :6, and 1 :8 (v / v) were tested under identical environmental conditions to assess their impact on growth rate, biomass development, structural quality, and material cost-efficiency.

[0135] The 1 :2 ratio resulted in the fastest colonization, with full substrate coverage achieved within 5-6 days. However, this ratio required a high volume of fungal culture, making it cost-inefficient and less scalable for production environments.

[0136] The 1 :6 ratio also enabled full colonization, albeit after a significantly longer incubation period of 9- 11 days. While growth was ultimately sufficient, the delay increases contamination risk and lowers throughput, making it a less favorable option, though still potentially applicable depending on the substrate composition.

[0137] The 1 :8 ratio demonstrated insufficient growth under the tested conditions. Colonization was slow and inconsistent, and structural formation was weak, rendering this ratio unsuitable for composite material production.

[0138] The 1 :4 ratio consistently offered the most favorable results in terms of growth kinetics and structural formation, achieving full colonization within 6-8 days. It provided a robust biomass yield, strong cohesion across the substrate, and scalability across multiple batches, making it the optimal ratio for textile waste-based substrates.

[0139] Algae Effect on Mycelium Growth

[0140] To evaluate the effects of algal co-cultivation and substrate supplementation on the performance of mycelium-based biocomposites, four experimental configurations were tested. Each configuration was prepared in 9 cm diameter sterile glass petri dishes using sterilized textile-waste- based substrates inoculated with Trametes versicolor. The co-cultivated algae cultures consisted of 150 mL of liquid Chlorella vulgaris grown in 250 mL Erlenmeyer flasks. Initial wet weights of each petri dish were recorded immediately after inoculation. Following the complete colonization phase final wet weights were measured using a precision analytical balance. Gravimetric and surface image analysis techniques were employed to quantify fungal biomass formation, substrate transformation, and surface colonization efficiency across all samples.

[0141] Gravimetric Assessment (Weight Loss Methodology)

[0142] To assess substrate transformation and fungal metabolic activity across different co-cultivation configurations, both initial and final wet weights of the biocomposite samples were measured using an analytical balance with high precision (±0.01 g). The purpose of this gravimetric method was to quantify weight loss during the growth phase, which reflects a combination of water evaporation, substrate digestion, and biomass transformation.

[0143] The percentage of weight loss is considered a proxy indicator for; fungal colonization efficiency, metabolic conversion of organic matter, moisture dynamics and system respiration. Surface Coverage via Image Analysis

[0144] In parallel, surface-level mycelial colonization was quantified through digital image analysis using ImageJ software. Standardized top-down photographs of each 9 cm petri dish were binarized (threshold >240) and analyzed for white pixel area representing visible mycelium growth. Each image was scaled using a known petri diameter (90 mm) to calculate absolute coverage area in cm2and relative coverage percentage of the total petri surface (~ 63.6 cm2).

[0145] This surface colonization metric complements the gravimetric results by revealing: fungal spread dynamics (2D growth behavior), homogeneity and density of colonization and edge coverage and morphology, relevant for panel applications.

[0146] Integrated Results and Interpretation

[0147] As shown in Table 1 , samples incorporating algal elements (C, D, E) consistently outperformed the mycelium-only control (B) in both biomass yield (dry weight loss) and surface colonization.

[0148] Table 1 . Biomass Formation and Surface Coverage in Mycelium-Algae Co-Cultivation Experiments.

[0149] Sample D, which combined both dried Chlorella vulgaris biomass in the substrate and live algal cocultivation, exhibited the highest mycelium coverage (62.62%) and one of the highest weight losses (23.10%), indicating maximized biological interaction and biomass formation.

[0150] Sample C, involving live algae only, also showed significantly greater colonization (54.23%) than the control, suggesting that algal-fungal gas-phase interaction enhances mycelial expansion.

[0151] Sample E, where only algal biomass was added without live culture, produced substantial weight loss (22.75%) but lower surface coverage (46.72%), implying greater internal biomass formation rather than surface colonization.

[0152] Control sample B consistently ranked lowest in both parameters, affirmingthe enhancement effect provided by algal components. These findings confirm that algal integration, particularly through dual input methods (D), improves both biomass productivity and surface development in mycelium-based composite materials. The combined analysis of gravimetric weight loss and surface colonization metrics supports the efficacy of co-cultivation in enhancing material performance within the scope of the present invention.

[0153] Enhanced Mechanical Properties Through Bio-Coating Application

[0154] The application of algal bio-coatingsignificantly enhances the mechanical properties of the mycelium-algae biocomposite material according to the present invention. Tensile strength measurements demonstrate substantial improvements, with coated samples exhibiting values ranging from 0.7 to 1.8 MPa compared to uncoated samples showing 0.4 to 1.2 MPa. The upper range (1 .2-1 .8 MPa) was achieved in samples subjected to both press consolidation and high polysaccharide-content algal extract coating under optimized hot-press conditions. In comparison, uncoated mycelium composites generally show tensile strengths between 0.01 and 1 .3 MPa depending on fungal strain, substrate, and processing conditions. Expanded polystyrene (EPS) exhibits values between 0.11 and 0.19 MPa, while most acoustic panel materials such as polyester or mineral wool composites exhibit tensile strengths below 1 MPa. Although particle board and MDF achieve tensile strengths between 8 and 18 MPa, they are non-biodegradable and rely on synthetic binders. Mycelium-based composites are generally limited in tensile performance; however, the application of algal bio-coatings and the incorporation of elongated textile fibers according to the present invention result in a significant enhancement in tensile strength within the biodegradable materials category.

[0155] Comparative Mechanical Performance Analysis

[0156] The biocomposite material without surface treatment exhibits tensile strength values in the range of 0.4 to 1 MPa. When the bio-coating comprising algal extracts or derivatives is applied according to step j of the method, the tensile strength increases to between 0.7 and 1.8 MPa, thereby demonstrating enhanced mechanical integrity of the biocomposite material.

[0157] However, when the bio-coating comprises dried algal biomass was directly applied without extraction, the biocomposite material exhibits tensile strength values ranging from 0.6 to 1.5 MPa, confirming the effectiveness of both coating methodologies disclosed herein.

[0158] Tensile Strength Measurement Methodology

[0159] Tensile strength measurements are conducted according to ASTM D638 standard using a universal testing machine equipped with a 5 kN load cell. Test specimens are prepared as Type I dog-bone shaped samples with dimensions of 165 mm total length, 13 mm width in the narrow section, and 3.2 mm thickness. The specimens are conditioned at 23°C ± 2°C and 50% ± 5% relative humidity for 40 hours prior to testing. Testing is performed at a crosshead speed of 5 mm / min until specimen failure. Load and displacement data are recorded continuously, and tensile strength is calculated as the maximum load divided by the original cross-sectional area of the narrow section.

Claims

CLAIMS1 . A method for producing biocomposite materials, the method comprisin the steps of a. providing a substrate suitable for mycelium growth, wherein the substrate comprises 80 to 90% small particle size textile waste supplemented with 10 to 20% elongated textile fibers by weight; b. sterilizing or pasteurizing the substrate; c. inoculating the substrate with a mycelium strain in a 4:1 to 6:1 v / v ratio; d. providing a liquid culture medium suitable for algae growth, enriched with essential nutrients; e. inoculatingthe liquid culture medium with an algae strain; f. co-cultivatingthe mycelium and algae in a controlled environment such that the mycelium grows on the solid substrate and the algae grow in the liquid culture medium, maintaining a temperature range of 20 to 30°C and a humidity level of 80 to 90 %, wherein additional algal biomass is added to the mycelium growing on a solid substrate in 0.5-15% of the substrate by weight relative to the substrate; g. allowing the mycelium and algae to interact during the growth period of 5 days to 4 weeks, thereby forming a biocomposite material comprising mycelium and algal biomass, with the algae constituting 0.5 to 30%, preferably 0.5 to 20% by weight of the total biomass; h. dehydrating the biocomposite material at 40-70°C for 8 to 72 hours to reduce moisture content; i. optionally pressing the dehydrated biocomposite under a hydraulic press at a pressure of 1-25 MPa to obtain a mycelium board; j. optionally applying a bio-coating to the mycelium biocomposite or board to enhance its durability and functionality, wherein the bio-coating comprises 5-15% algal extracts or derivatives by weight (algae-derived bioactive compounds); and k. drying and curing the biocomposite material at 40-70°C for 8- 72 hours to enhance its structural integrity and durability.

2. The method of claim 1 , wherein the sterilization in step b is performed at a temperature range of 100°C to 130°C for 20 to 60 minutes using autoclave, steam chamber, or pressure-based sterilization.

3. The method of claim 1 , wherein the mycelium strain is selected from basidiomycetes.

4. The method of any one of claims 1 to 3, wherein the mycelium strain is preferably selected from the group consisting of Pleurotus ostreatus, Ganoderma lucidum, Trametes versicolor, and Agrocybe cylindracea.

5. The method of any one of claims 1 to 4, wherein the small particle size textile waste has an average particle diameter of approximately 0.3 cm, preferably ranging between 0.1 cm and 0.5 cm.

6. The method of any one of claims 1 to 5, wherein the elongated textile fibers are incorporated in mesh-like arrangements with lengths adjusted to be approximately 1 cm shorter than the target composite panel width and height, enabling internal structural reinforcement.

7. The method of any one of claims 1 to 6, wherein the elongated textile fibers have diameters ranging from 10 to 100 micrometers.

8. The method of any one of claims 1 to 7, wherein the added textile waste and elongated textile fibers in step a comprises preferably of cotton or polyester or hemp or wool or viscose or a combination thereof.

9. The method of any one of claims 1 to 8, wherein step c preferably has a ratio of 4:1 v / v.

10. The method of any one of claims 1 to 9, wherein the algae strain is preferably selected from the group consisting of Chlorella vulgaris, Scenedesmus vacuolatus, Nannochloropsis gaditana, Botryococcus braunii, Arthrospira platensis, Kirchneriella lunaris and Laminaria spp.11 . The method of any one of claims 1 to 10, wherein the algae strain is preferably selected from the group consisting of Scenedesmus vacuolatus, Nannochloropsis gaditana, Arthrospira platensis, and Kirchneriella lunaris.

12. The method of any one of claims 1 to 11 , wherein the additional algal biomass added in step f is selected from Chlorella vulgaris, Chlorella variabilis, Chlorella pyrenoidosa, Kirchneriella lunaris, Staurastrum spp., Scenedesmus vacuolatus, Nannochloropsis gaditana, Botryococcus braunii, Arthrospira platensis, Laminaria spp., Gracilaria spp., and Ulva spp.

13. The method of any one of claims 1 to 12, further comprising in step a, the step of supplementing the substrate with a 5-10% mixture selected from cotton, algal biomass, hemp, oat, rice, millet, rye, wood waste, sawdust, wood shavings, straw, tea, coffee, brewery wastes, bacterial cellulose, paper sludge, marble powder, calcite, pearlite, vermiculite, regolith, by weight relative to the substrate to enhance mycelium growth.

14. The method of any one of claims 1 to 13, wherein the bio-coating in step j is selected from algae-derived bioactive compounds, preferably comprising of at least one algal polysaccharide, algal lipids, algal proteins, and algal pigments, providing UV protection, water resistance, and antimicrobial properties to the biocomposite material.

15. The method of any one of claims 1 to 14, wherein the dehydration step in step k at 40-70°C for 8- 72 hours ensures the reduction of moisture content to less than 10%, which provides durability and structural integrity of the biocomposite material.

16. The method of any one of claims 1 to 15, wherein the bio-coating is prepared by harvesting and dryingthe algal liquid culture under controlled conditions to obtain algal biomass, and formulating the dried biomass into a bio-coating solution by suspending it in an aqueous or hydroalcoholic solution containing a natural biopolymer binder selected from sodium alginate or agar.

17. The method of claim 16, wherein the bio-coating solution optionally incorporates hydrophobic additives selected from plant oils or wax emulsions to improve water resistance.

18. The method of claim 1 or 16-17, wherein the bio-coating is applied to the surface of the dehydrated mycelium composite using methods selected from spray coating, brushing, or dipcoating, with a coating layer thickness of 0.1 mm to 0.5 mm.

19. A mycelium-algae biocomposite prepared using the method of any one claims 1 to 18.

20. The biocomposite of claim 19, further comprising elongated textile fibers having a diameter ranging from 10-100 micrometers in diameter that enhance the structural strength of the biocomposite material by a range of 10 to 40%.21 . Use of the biocomposite material of claim 19 or 20 in the production of mycelium-algae based materials suitable for interior design elements as an alternative to wood and plastic materials, serving as a substitution for particle boards and plastic foams.

22. A system for producing biocomposite materials, comprising: a substrate preparation unit for preparing and sterilizing a substrate suitable for mycelium growth, wherein the substrate comprises small particle size textile waste supplemented with elongated textile fibers; a mycelium inoculation unit for inoculating the substrate with a mycelium strain; a liquid culture preparation unit for preparing a liquid culture medium suitable for algae growth; an algae inoculation unit for inoculating the liquid culture medium with an algae strain; a co-cultivation chamber configured to maintain a controlled environment for the simultaneous growth of mycelium on the substrate and algae in the liquid culture medium; a dehydration unit for reducing the moisture content of the biocomposite material; a hydraulic press for pressingthe dehydrated mycelium-algae composite to obtain a mycelium board; a bio-coating application unit for applying a bio-coating comprising algal extracts or derivatives to the mycelium board, wherein sensors and monitoring systems track the growth of mycelium and algae, adjust environmental conditions accordingly, and ensure the interaction ratio of algae culture to mycelium substrate is preferably maintained within the range of 1 :5 to 4:1 (v / v).

23. The system of claim 22, wherein the substrate preparation unit comprises grinding equipment capable of processing textile waste to achieve particle sizes ranging from 0.1 to 0.5 cm and sieving mechanisms with mesh sizes correspondingto the target particle size distribution.

24. The system of claim 22 or 23, wherein the co-cultivation chamber includes separate compartments for solid-state mycelium cultivation and liquid-state algae culture with gas exchange systems facilitating oxygen and carbon dioxide transfer between compartments.

25. The system of any one of claims 22 to 24, wherein the monitoring systems include temperature sensors, humidity sensors, pH meters for algal culture monitoring, dissolved oxygen sensors, and optical density measurement systems for algal growth tracking with automated control systems that adjust environmental parameters based on sensor feedback.

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