Methods of producing mycelium-based products, mycelium-based product, and industrial applications thereof

Abstract

The present invention relates broadly to methods of producing Mycelium-based materials, to Mycelium-based products, and industrial applications thereof. Non-limiting example embodiments of the present invention aim to enhance the production process of a mycelium-based composite by employing a combination of specific mechanical, chemical and manufacturing processing techniques to improve the bonding between the mycelium hyphae and the substrates and / or to enhance the microstructure of the final composite / product and / or to enhance production efficiency of final composite / product.

Description

[0001] METHODS OF PRODUCING MYCELIUM-BASED PRODUCTS, MYCELIUM-BASED PRODUCT, AND INDUSTRIAL APPLICATIONS THEREOF

[0002] FIELD OF INVENTION

[0003] The present invention relates broadly to methods of producing Mycelium-based materials, to Mycelium-based products, and industrial applications thereof.

[0004] BACKGROUND

[0005] The buildings and construction industry is currently the largest contributor to global greenhouse gas emissions, responsible for about 40% of the total [https: / / www.unep.org / resources / report / building-materials-and-climate-constructing-new- future]. The production of key materials like cement, steel, and aluminium leaves behind a hefty carbon footprint. Traditionally, the industry's efforts have focused on cutting "operational" carbon emissions — those that come from everyday functions like heating, cooling, and lighting. Yet, addressing "embodied" carbon emissions — those generated during the design, production, and use of building materials — has been slower to gain momentum. Tackling this issue will require a concerted, global effort that unites all players across the sector, working together through every phase of the building lifecycle in both formal and informal collaborations.

[0006] To tackle the impacts of construction and other materials-intensive industries on climate change there is a need to find alternative sustainable and resource-efficient materials.

[0007] Mycelium-based composite materials as a class of advanced biomaterials are produced by growing fungal mycelia of at least one species of commercially cultivated mushrooms on different discrete organic and inorganic substances mainly sourced from wood waste, food and agricultural waste products. Mycelium comprises thread-like hyphae which works as a binder to interconnect through and around its growing substrate. Subsequent products can be affordable, environmentally friendly and recyclable for a wide range of applications.

[0008] There are currently a range of mycelium-based materials available in the market with a focus on packaging, insulation, leather and alternative protein products. The main line of the current mycelium-based products is based on commercially available mushroom species combined with wood and / or hemp and / or straw fibers as substrates. While packaging and insulation Products are typically lightweight, they possess low mechanical strength which does not allow their application as an alternative to e.g. wood-based panels or other heavy duty applications.

[0009] Existing mycelium-based products are dependent mainly on one or two specific substrates for their growth such as wood particles and hemp. Another limitation associated with the current developments in mycelium material production is the limitation to grow the mycelium materials in the desired form for several days which would raise issue with price and scalability of mycelium materials production.

[0010] Another significant limitation of current mycelium-based materials lies in their scalability. The fabrication methods presently available are often labor-intensive or difficult to scale efficiently, leading to increased production costs and limiting their ability to meet industrial demand at the scale necessary to make a substantial impact.

[0011] Embodiments of the present invention seek to address at least one of the above problems.

[0012] SUMMARY

[0013] In accordance with a first aspect of the present invention, there is provided a method of fabricating a mycelium-based product comprising the steps of: injecting a fibrous material comprising crushed mycelium colonized substrate material into a form for the product; and curing the fibrous material in the form; wherein the curing comprises at least one of applying heat, applying pressure, or allowing growth of the mycelium colonized substrate material.

[0014] In accordance with a second aspect of the present invention, there is provided a myceliumbased product comprising a cured fibrous material comprising crushed mycelium colonized substrate material cured in a form for the product.

[0015] In accordance with a third aspect of the present invention, there is provided a method of fabricating a mycelium-based product comprising the steps of: providing a substrate; inoculating the substrate with mycelium; growing the mycelium on the substrate in a form for the product; and curing the grown mycelium for termination of growth; wherein the method comprises intermittent application of pressure during the growing of the mycelium prior to the curing.

[0016] In accordance with a fourth aspect of the present invention, there is provided a myceliumbased product, fabricated using the method according to the third aspect.

[0017] In accordance with a fifth aspect of the present invention, there is provided a method of fabricating a mycelium-based product comprising the steps of: providing a substrate; inoculating the substrate with mycelium; growing the mycelium on the substrate in a form for the product; and curing the grown mycelium for termination of growth; wherein the method comprises cementation of the product before, as part of, or after the curing.

[0018] In accordance with a sixth aspect of the present invention, there is provided a myceliumbased product, fabricated using the method according to the fifth aspect.

[0019] In accordance with a seventh aspect of the present invention, there is provided a method of fabricating a mycelium-based product comprising the steps of: providing a substrate; inoculating the substrate with mycelium; growing the mycelium on the substrate in a form for the product; and curing the grown mycelium for termination of growth; wherein the method comprises attaching a veneer layer to a surface of the grown mycelium prior to termination of growth, preferably without requiring an additional binder material, or attaching a veneer layer to a surface of the grown mycelium after termination of growth using an additional binder material.

[0020] In accordance with an eighth aspect of the present invention, there is provided a myceliumbased product comprising: grown mycelium; and a veneer layer attached to the surface of the grown mycelium.

[0021] In accordance with a nineth aspect of the present invention, there is provided a method of fabricating a mycelium-based product comprising the steps of: providing a substrate; inoculating the substrate with mycelium; growing the mycelium on the substrate in a form for the product; and curing the grown mycelium for termination of growth; wherein the method comprises intermittent release of a pressure applied during the curing.

[0022] In accordance with a tenth aspect of the present invention, there is provided a myceliumbased product, fabricated using the method according to nineth aspect.

[0023] In accordance with an eleventh aspect of the present invention, there is provided a method of producing a mycelium-based binder, comprising: providing a substrate; inoculating the substrate with mycelium; growing the mycelium; harvesting the grown mycelium in the form of a biomass as the mycelium-based binder; and curing the biomass to terminate growth.

[0024] In accordance with a twelfth aspect of the present invention, there is provided a composite material comprising: a fibrous or granular substrate selected from one or more of a group consisting of wood fibers, cellulose fibers, agricultural fibers, wood chips, husks, and straw; and a mycelium binder fabricated by a method according to the eleventh aspect; wherein the mycelium binder bonds the substrate into the composite material.

[0025] In accordance with a thirteenth aspect of the present invention, there is provided a method of using the mycelium binder according to the eleventh aspect as an adhesive for producing fiber-based or granular-based composite material.

[0026] In accordance with a fourteenth aspect of the present invention, there is provided a method of producing a mycelium -based veneer layer, comprising the steps of: providing a substrate; inoculating the substrate with mycelium; growing the mycelium; harvesting the grown mycelium in the form of one or more skin layers as the mycelium-based veneer layer; and curing the veneer layer to terminate growth.

[0027] In accordance with a fifteenth aspect of the present invention, there is provided a composite material comprising: a fibrous or granular substrate selected from one or more of a group consisting of wood fibers, cellulose fibers, agricultural fibers, wood chips, husks, and straw; and a mycelium veneer fabricated by a method according to the fourteenth aspect; wherein the mycelium veneer covers a surface of composite material.

[0028] In accordance with a sixteenth aspect of the present invention, there is provided a method of fabricating a mycelium-based composite product, comprising: providing a mycelium-based material comprising a mycelium-colonized substrate, the material being either (i) a crushed fibrous substrate injected into a form, or (ii) a substrate grown directly in a form; and curing the mycelium-based material by alternating hot and cold pressing steps.

[0029] In accordance with a seventeenth aspect of the present invention, there is provided a mycelium-based composite product fabricated by the method according to the sixteenth aspect.

[0030] BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Embodiments of the invention will be better understood and readily apparent to one of ordinary skill in the art from the following written description, by way of example only, and in conjunction with the drawings, in which:

[0032] Figure 1 shows a diagram illustrating development of mycelium materials such as myceliumbased brick and composite building elements according to example embodiments.

[0033] Figure 2 shows a diagram illustrating development of mycelium-based composite material through the process of cementation, where organic / inorganic cement based solution and / or powder can be added to the composite in either dry or wet condition, according to example embodiments.

[0034] Figure 3A shows a diagram illustrating development of high density mycelium-based composite materials with properties similar to Plywood, MDF and chipboard panels, according to example embodiments.

[0035] Figure 3B shows a photograph of contaminated wood waste from furniture industry.

[0036] Figure 3C shows a photograph illustrating using mycelium materials pre-grown in shape, according to an example embodiment.

[0037] Figure 3D shows a photograph illustrating using several pieces of mycelium-based material interlocked or beside each other, according to an example embodiment. Figure 3E shows a photograph illustrating a final mycelium-based element after producing with either technique of Figures 3B, D, according to an example embodiment.

[0038] Figure 3F shows delamination and Figure 3G shows the absence of delamination.

[0039] Figure 4A shows a diagram illustrating a production technique using injection, such Fiber Injection Molding (FIM), in the production of mycelium -based products, according to example embodiments.

[0040] Figure 4B shows a photograph illustrating fibers inoculated with mycelium being injected into a form, according to an example embodiment.

[0041] Figure 4C shows a photograph illustrating fibers inoculated with mycelium being having been injected into a form, according to an example embodiment.

[0042] Figure 4D shows a photograph illustrating fibers inoculated with mycelium being and injected into a form being subjected to a heat-press technique, according to an example embodiment.

[0043] Figure 4E shows a photograph of a three-dimensional dense mycelium board produced with such a combination of fiber injection molding and heat-press technique, according to an example embodiment, produced with varying density along the edge for improvement of stiffness.

[0044] Figure 4F shows a photograph of a similar board as in Figure 4E, produced without higher density of edges, which shows breakage of the edges.

[0045] Figure 5 shows a diagram illustrating a process in which mycelium is grown in bulk forms in a mushroom growing facility and the colonized substrate can be processed in 3 different ways for production of composites / products, according to example embodiments.

[0046] Figure 6 shows a diagram illustrating a process for fabricating a dense mycelium board, including usage of binder matrixes for attachment of mycelium layers prior to pressing and / or reinforcing the top, middle and bottom layers of the dense mycelium board with natural fibers and / or fiber-based composite board (e.g. bamboo composite) and / or natural timber and / or engineered timber products (e.g. glue laminated timber) and / or using synthetic or natural veneers (e.g. wood veneer) by using an adhesive matrix and subsequently applying adequate amount of pressure with or without heat to create a hybrid system, according to example embodiments.

[0047] Figure 7 shows a diagram illustrating a process in which mycelium can be grown to produce a pure mycelium binder, a 100% natural adhesive, according to an example embodiment.

[0048] Figure 8 shows a diagram illustrating a mycelium-veneer production process, according to example embodiments. Figure 9 shows a diagram illustrating cured skin layers can be overlaid in a specific form and subjected to high pressure and heat, for the formation of a denser board with increased binding between the individual layers through the application of pressure and heat, according to example embodiments.

[0049] Figure 10 shows a diagram illustrating the complete supply chain of mycelium materials, according to example embodiments.

[0050] Figure 11 shows a schematic drawing illustrating a portion of the production process related to the veneer attachment to light-weight mycelium composite, according to an example embodiment.

[0051] Figure 12A shows a photograph of a seat plate for a chair element exhibiting varying density along edges (such as circled area), resulting from differences in the combination of pressure and heat during stages of production, according to an example embodiment.

[0052] Figure 12B shows a photograph of a lightweight mycelium-based shell with locally increased density in sensitive or thin corner regions (for example circled area), produced by allowing post-growth in a bottom mold or form with a corresponding top mold or stamp disposed at a certain height above the height of the initially injected fibers inoculated with mycelium, according to an example embodiment.

[0053] Figure 13 A shows a photograph taken on day 0 of producing a light weight mycelium composite according to an example embodiment.

[0054] Figure 13B shows a photograph taken on day 2 after development of mycelium network when intermittent pressing starts, according to an example embodiment.

[0055] Figure 13C shows a photograph taken on day 3 illustrating the partially pressed growing mycelium-based material, according to an example embodiment.

[0056] Figure 13D shows a photograph taken on day 4 illustrating full pressed growing myceliumbased material, according to an example embodiment.

[0057] Figure 13E shows a photograph illustrating the fully grown mycelium-based material grown under intermittent pressing, according to an example embodiment.

[0058] Figure 13F shows a photograph of a compression system used according to an example embodiment.

[0059] DETAILED DESCRIPTION

[0060] Embodiments of the present invention are related to the fabrication methods of biocomposite materials which are based on discrete food, forest and agricultural waste substances and / or wood waste and / or hard aggregates and / or polymers bound / reinforced using the interconnecting network of fungal mycelia of at least one species of fungi with / without using any additional binding agents. The final composite’ s / product’s physical and mechanical properties can vary to address different range of applications such as, but not limited to, construction, furniture, interior design, logistic, car, sport, water, toy, stationery and paper industries. In some example embodiments, the mycelium of fungal species of interest can also be grown on liquid and / or gelatinous and / or hydrogel substrate to be used solely or in combination with other agents as 3 dimensional (3D) printing ink and / or binder instead of synthetic binders for composite / product fabrication or 3D printing.

[0061] Embodiments of the present invention aim to enhance the production process of a myceliumbased composite by employing a combination of specific mechanical, chemical and manufacturing processing techniques to improve the bonding between the mycelium hyphae and the substrates and / or to enhance the microstructure of the final composite / product and / or to enhance production efficiency of final composite / product.

[0062] Embodiments of the present invention aim to provide a circular bioeconomy production process, resourcing mainly waste materials from diverse industries and producing high value products which can go back to the production cycle of the specific industry. Embodiments of the present invention also provide a circular supply chain for commercialization of products.

[0063] In addition to providing an extension of the type of substrates that can be used, embodiments of the present invention aim to use variety of mushroom species to produce mycelium-based composite materials. This can enhance the production of these composites for different geographical regions and with respect to the available fungal species suitable for specific regions. Such flexibility supports decentralized manufacturing and facilitates scalable, adaptable, and regionally impactful production. Embodiments of the present invention have shown that variety of fungal species that grow on organic waste can be used for this purpose that will result in products of different properties for various applications.

[0064] Utilizing extensive fibrous resources across varying size ranges to produce mycelium materials allows for the optimization of fiber size distribution. This optimization is advantageous, as the distribution of fiber sizes in the composite can significantly impact the final density, porosity, and mechanical performance. Additionally, when using a single type of fiber, sieving and / or milling the fibers before colonizing them with mycelium can further enhance fiber size distribution. This process influences the density of the mycelium network and the material's behavior during forming and pressing processes. In example embodiments of the present invention, the mechanical properties of the produced composite / product can be tailored with respect to the final application.

[0065] Furthermore, embodiments of the present innovation can enable overlaying different layers of mycelium-based composite with or without natural fiber in between layers with the aid of mycelium as a natural binder matrix to reinforce the composite and to develop laminated fiber composites without any synthetic binders. This can enhance the mechanical and physical properties of the mycelium-based composites / products and can permit its usage in a wide range of applications from non- structural to structural applications, which current processes cannot provide. In addition, embodiments of the present innovation aim to replace the conventional building materials specifically particleboards, Medium Density Fiber (MDF), Medium Density Overlay (MDO) and Oriented Strand Board (OSB), most of which are produced with energy intensive production process and non-renewable binders and therefore are no longer considered as sustainable green products. Mycelium-based composites are cheaper and more environmentally friendly compared to such existing products.

[0066] Embodiments of the present innovation can address the existing challenge of re-using and recycling of the waste especially from food, wood and agricultural industry to be integrated into the growth of the fungal mycelium and to create high performance mycelium-based composites / products for applications in, for example, building and furniture and water industries. Embodiments of the present innovation were found to use less amount of energy compared to existing alternatives, while using the waste by products of wood and / or agricultural and / or horticultural industry as the raw materials for production without the need to use any freshly cut timber or fibers. Embodiments of the present invention can be independent of forming stage, which can not only reduce the production cycle, resources, and space, but can also enable to directly use the colonized mycelium substrate before or after fruiting stage.

[0067] Compared to traditional engineered wood products including OSB, MDF, Particleboards, embodiments of the present invention can avoid the need for synthetic resin / binders and make the production of a fully biobased alternative possible with the help of mycelium as a biobased binder.

[0068] In addition, the embodiments of the present invention can enable the use of treated industrial wood waste which is usually contaminated with plastic and coatings. Mycelium can secrete enzymes that could potentially break down the long-chain polymers found in plastics into simpler molecules, which can then be further metabolized, see e.g. Zurbano LY, Castaneda LM, Dorado RM, Heresano KM, Lloyd SH, Pante MD. Mycelial growth, yield and decomposition capability of white oyster mushroom (Pleurotus florida) grown in low-density polyethylene (LDPE) plastic and lignocellulosic wastes. Journal of Applied Horticulture. 2024 May 1;26(2). Therefore, with the technology in such example embodiments, treated wood waste or other contaminated resources could not only be upcycled for industrial application, but their contamination could also be reduced fully or partially through the mycelium growth. Such example embodiment may be a game changer for industries which are dealing with contaminated wood and agricultural waste such as but not limited to furniture industry. Figure 3B shows a photograph of such contaminated wood waste 360, 362, 364 from furniture industry.

[0069] Compared to existing mycelium-based production processes for composites, embodiments of the present invention can have tailored mechanical properties, including higher-strength mechanical properties and better durability and with properties similar to, if not better than, MDF, OSB, Particleboards, chipboards and even injected-molded plastic parts, enabling a direct replacement for those wood-based panels and formed plastics. Existing mycelium- based composites are mostly lightweight and use very limited range of substrates and fungal species and are mainly based on the combination of hemp fibers and wood chips. Existing mycelium-based technologies are not able to re-place wood-based panels or molded plastic products given their limited properties and characteristics.

[0070] Current technologies primarily focus on growing mycelium into specific shapes for several days before post-processing them. Example embodiments of the present invention can use advanced digital manufacturing techniques to create composites in a desired shape using pregrown mycelium in minutes. This can advantageously eliminate the need to regrow the mycelium, allowing for greater efficiency and flexibility in design.

[0071] The processing methods that distinguish embodiments of the present invention are described in more detail with reference to Figures 1 to 13 below.

[0072] Different processes in which Mycelium-based composite materials as the future generation of materials can be fabricated according to example embodiments can address different applications with varying properties. Embodiments of the present invention also provide a supply chain model for commercialization of mycelium-based composite materials (Figure 10).

[0073] With reference generally to Figure 1, to develop mycelium materials such as mycelium-based brick and composite building elements according to example embodiments of the present invention firstly the substrate is prepared from a variety of food and / or agricultural and / or wood waste resources (e.g. sawdust, bamboo and coconut fiber, sugarcane, kenaf, hemp, brewery waste, coffee bean waste, Miscanthus, Pallet waste, treated and untreated wood waste and etc). The substrate can be mixed with almost any form of aggregates including but not limited to seashell, coconut shell, egg shell, recycled aggregates from construction, cherry stone and etc to improve the mechanical properties of the final composite. The enhancement to the properties of the final composite can be further carried out by incorporating natural binding polymers such as chitin extracted from seashells and / or fungi to the final media for the growth of the mycelium. In the next step, adequate amount of water will be added to the growth media and subsequently it will be sterilized in an autoclave or through other methods such as pasteurization. In the next step the liquid and / or solid culture of the mycelium of at least one of the species of commercially cultivated mushrooms such as Genoderma Lucidum, Fomitopsis officinalis, Fomotopsis pinicola, Fomes fomentarius, Piptoporus betulinus, Ganoderma applantum, Trametes versocolar, Pleurotus pulmonarius, Hericium erinaceus, ganoderma lucidum, Grifola frondosa, and Pleurotus osterous is added to the sterilized growth media. Preferably, the commercially cultivated mushrooms are non-hazardous, for example they preferably are “edible” in the sense that they are suitable for consumption either as food or for medicinal and pharmaceutical purposes, i.e. including for use in extracts, supplements, or other pharmaceutical products.

[0074] In the next step, the initial growth of the media will take place in plastic logs or modular forms or bulk at certain temperature and humidity condition depending on the species of the mycelium used during inoculation process. Following the initial growth of required time span between 3 to 14 days, the colonized substrate will be crushed into finer particles to fill the form of preferred shape for another phase of mycelium hyphae growth. To achieve a lightweight composite material, the form can be removed after an additional 1 to 5 (depending on the properties needed and the type of substrate and fungi in some cases more than 5 days is needed however generally it is less than 5 day and this applies to the other embodiments presented here) days to let the chitinous skin grow further around the surface of the composite material under suitable environmental condition defined by the species of the mushroom used, with or without adding an extra source of binder(s). Thereafter the mycelium composite will be dried in an oven under temperature range of 45C to 85C to terminate the growth of the mycelium. The drying stage could be altered in various example embodiment given the size and density of the final products. For example, to reduce shrinkage the product could be air dried with ventilation in temperature below 45 C or even room temperature prior to exposure to heat. On the other hand, the composite could also be fast-dried under temperature above 85 degrees, however this may not be preferred due to the excessive required energy and possible shrinkage and deformation of the product.

[0075] To achieve a dense composite structure, a certain amount of incremental pressure is applied to the form in one to three steps to increase the density and reduce the porosity. The pressure will be kept on the form for another e.g. 1-5 days (depending on the properties needed and the type of substrate and fungi in some cases more than 5 days is needed however generally it is less than 5 day) before it can be released. By releasing the pressure and removing the form the chitinous skin can grow further specially on to the surface of the composite material. Thereafter the mycelium composite will be dried in an oven under temperature range of 45C to 85C to terminate the growth of the mycelium. The drying stage could also be altered in various example embodiments, as mentioned above. If there is a need to prevent humidity, UV, termite and / or fire resistance, commercially available coatings, minerals and natural oil (e.g. tea tree oil) can be used.

[0076] In more detail, Figure 1 shows structural / non- structural brick production, according to various example embodiments.

[0077] For feedstock preparation 100.

[0078] Substrate preparation 102 comprises processing food and / or agricultural waste and / or wood waste to discrete particles with certain size distribution as the growth media for mycelium.

[0079] Aggregates 104 comprises incorporating aggregates such as sand into the organic substrate or as a stand-alone nutrient media for mycelium growth. Aggregates 104 can comprise inorganic aggregates such as sand, glass particles, ceramic beads, or crushed stone into the organic substrate or as a stand-alone medium for mycelium growth, wherein said aggregates enhance structural properties including dimensional stability, compressive strength, or thermal mass. In experiments it was found that adding only 10% of sand particles to the substrate would enhance the compressive strength by 50% and the modulus of elasticity by 100%, according to a non-limiting example embodiment. Minerals 106 comprises incorporating minerals such as silicon and metals in to the growth media to provide additional fire safety and antimicrobial properties to the mycelium block, as desired. Minerals 106 can comprise mineral additives such as silica, silicates, or antimicrobial metals including copper, silver, or zinc into the growth media to provide enhanced fire resistance and antimicrobial properties to the mycelium composite block. In experiments it was found that adding 5% of silicate to the substrate would enhance the compressive strength by 20% and the modulus of elasticity by 100%, according to a non-limiting example embodiment.

[0080] Bulk treatment 108 comprises optionally incorporating one or more natural polymers into the fungal nutrient substrate, wherein the natural polymer is selected from (one or more of):

[0081] • chitin or chitosan;

[0082] • mycelium binder (see also description of Figure 7 below);

[0083] • spent mushroom substrate (SMS);

[0084] • protein-based polymers (e.g., zein, keratin, gluten, gelatin);

[0085] • plant-derived gums (e.g., guar gum, gum arabic, tragacanth);

[0086] • polyphenolic biopolymers (e.g., tannins, suberin);

[0087] • marine and algal polysaccharides (e.g., alginate, agar, carrageenan, fucoidan, ulvan);

[0088] • fruit- or plant-derived waxy biopolymers (e.g., cutin)..

[0089] In experiments it was found that adding 5% of chitosan to the original substrate enhances both the compressive strength and modulus of elasticity by 200%, according to a nonlimiting example embodiment.

[0090] Following feedstock preparation 100, hydration and sterilization 108 comprises adding adequate amount of water to the growth media and sterilize it in an autoclave / pasteurization chamber / self-bulk heating / hydrating the substrate in a disinfectant solution (e.g. 3% hydrogen peroxide solution) and draining the liquid.

[0091] Next, inoculation 110 comprises introducing liquid culture or solid spawn or mycelium from agar plate into the clean sterilized growth media.

[0092] Next, substrate colonization 112 comprises initiating the growth in plastic logs / trays / modular forms / bulk growth / biologically compatible 3D printed scaffold at the appropriate environment. The environment depends on the type of mycelium and substrate used but may be in a temperature range of 20C to 30C, relative humidity of 60% to 99%, time between 3 to 10 days. Its is noted that “bulk growth” here means colonizing substrate in large continuous volumes (containers, trays, rooms) rather than in individual bags or forms. This enables scalable production, more uniform network formation, and the option to process the bulk mass (e.g., cut or densify) after growth. It is noted that “3D-printed scaffold” here means engineered, biocompatible, and sustainable supports (e.g., hydrogels, textiles, wood veneer, bioplastics) that become part of the final material. They guide mycelial growth into complex forms, allow lightweight or modular structures, and enable functions (ventilation channels, gradients) that molds cannot. Because the scaffold integrates into the material, production is faster and more efficient with reduced waste and more applicable to digital manufacturing technologies like Fiber Injection Molding (FIM), as will be described in more detail below.Hence, optionally, forming 114 comprises crushing the colonized substrate and forming into the preferred form or printed scaffold for re- growing the mycelium hyphae network / injecting the colonized substrate in the form or printed scaffold using Fiber Injection Molding (FIM) and / or 3D printing. In some embodiments, the fibrous material may also be processed in a mold-free manner, for example by additive manufacturing or direct 3D printing. In such cases, scaffolding or temporary support structures can replace the mold to guide the deposited fibers, or supplementary binders, pastes, or inks can be incorporated into the fibrous stream to enable controlled deposition. This allows fabrication of complex geometries similar to fiber injection molding but without requiring a solid mold.

[0093] In some embodiments of the methods and products described herein, one or more of the steps of sterilization 109, inoculation 110, and colonization 112 may be carried out directly within a form or mold used for shaping the final product. In such embodiments, the substrate can be sterilized, inoculated, and grown in situ, allowing the mycelium to colonize and bind the substrate within the intended geometry of the form. These steps may therefore occur partially or fully concurrently with forming 114. This integrated approach represents one possible configuration within the general process and can reduce handling, improve shape fidelity, and eliminate the need to transfer colonized material into a separate mold, while remaining compatible with any of the curing or pressing methods described herein.

[0094] At 116, different options include dense material production and lightweight material production.

[0095] Dense material production according to an example embodiment.

[0096] Pressure 117 comprises applying pressure on the mycelium after initial reformation of the network in the mold, but before final curing, to increase density and reduce porosity. In experiments it was found that applying a nominal pressure of 0.2 MPa would densify the sample by 100%, according to a non-limiting example embodiment. It is noted that this varies given the starting density, type of substrate and size of the specimen in different example embodiments.

[0097] It is noted that the timing of applying the pressure can be based on a visual assessment of the reformation of the network, e.g. transition towards a uniform colour based on the Mycelium network reformation.

[0098] Figure 13 A shows a photograph taken on day 0 of producing a light weight mycelium composite in a form 1302 according to an example embodiment. Figure 13B shows a photograph taken on day 2 after development of mycelium network when intermittent pressing starts, according to an example embodiment. Figure 13C shows a photograph taken on day 3 illustrating the partially pressed growing mycelium-based material, according to an example embodiment. Figure 13D shows a photograph taken on day 4 illustrating full pressed growing mycelium-based material, according to an example embodiment. Figure 13E shows a photograph illustrating the fully grown mycelium-based material grown under intermittent pressing, according to an example embodiment. Figure 13F shows a photograph of a compression system 1304 used according to a non-limiting example embodiment.

[0099] In one embodiment, a method of fabricating a mycelium-based product comprises the steps of providing a substrate; inoculating the substrate with mycelium; growing the mycelium on the substrate in a form for the product; and curing the grown mycelium for termination of growth; wherein the method comprises intermittent release of a pressure applied during the curing.

[0100] The pressure during curing may be about 1 MPa or higher.

[0101] The curing may be performed in a temperature range of about 100 °C or higher.

[0102] In one embodiment, a mycelium-based product, fabricated using the method according to the embodiment described above is provided. Optionally, stacking 118 comprises stacking the modular composites after growing to weld them biologically through mycelium growth for additional days.

[0103] Optionally, pressure removal and skin development 120 comprises releasing the pressure from the mycelium composite and removing the form at the same time for further development of mycelium skin on the outer surface.

[0104] Following any of 117, 118, or 120, curing 122 comprises drying the mycelium composite in certain range of temperature for termination of the growth until the humidity of the composite is preferably less than 10%.

[0105] Lightweight material production according to an example embodiment.

[0106] Optionally, stacking 124 comprises stacking the modular composites after growing to weld them biologically through mycelium growth for additional days.

[0107] Optionally, skin development 126 comprises form removal for additional (e.g. 1 to 5 days) for more chitinous skin development around the composite in the right environment. The environment depends on the type of mycelium and substrate used but may be in a temperature range of 20C to 30C, relative humidity of 60% to 99%, time between 3 to 10 days.

[0108] Following any of 124, 126, curing 128 comprises drying the stacked mycelium composite or individual composites in specific temperature, e.g. under temperature range of 45C to 85C, for termination of the growth until the humidity of the composite preferably is less than 10%. Next, in either one of the dense or lightweight production process, following either 122 or 128, if additional humidity, UV, mite and / or fire retardancy are required, the relevant coating(s) are applied at 130 prior to the material being ready for use. If not, the material is ready for use at 132.

[0109] Further improvement of the mycelium-based composite material can be carried out according to various example embodiments through the process of cementation, where organic / inorganic cement based solution and / or powder can be added to the composite in either dry or wet condition as described in Figure 2.

[0110] In more detail, Figure 2 shows brick reinforcement with cement, according to various example embodiments. Same reference numerals used in Figure 2 indicate the same elements as described above with reference to Figure 1. Briefly:

[0111] For feedstock preparation 100.

[0112] Substrate preparation 102 comprises processing food and / or agricultural waste and / or wood waste to discrete particles with certain size distribution as the growth media for mycelium.

[0113] Aggregates 104 comprises incorporating aggregates into the organic substrate or as a standalone nutrient media for mycelium growth.

[0114] Minerals 106 comprises incorporating minerals such as silicon and metals in to the growth media to provide additional fire safety and antimicrobial properties to the mycelium block, as desired.

[0115] Bulk treatment 108 comprises optionally incorporating natural binding polymers such as chitin extracted from seashells and / or fungi or lignin in to the fungi nutrient media.

[0116] Following feedstock preparation 100, hydration and sterilization 109 comprises adding adequate amount of water to the growth media and sterilize it in an autoclave / pasteurization chamber / self-bulk heating / hydrating the substrate in a disinfectant solution (e.g. 3% hydrogen peroxide solution) and draining the liquid.

[0117] Next, inoculation 110 comprises introducing liquid culture or solid spawn or mycelium from agar plate in to the clean sterilized growth media.

[0118] Next, substrate colonization 112 comprises initiating the growth in plastic logs / trays / modular forms / bulk growth / biologically compatible 3D printed scaffold at the appropriate environment. The environment depends on the type of mycelium and substrate used but may be in a temperature range of 20C to 30C, Relative humidity of 60% to 99%, time between 3 to 10 days. Colonization of fibers could also directly happen in forming (114).

[0119] Optionally, forming 114 comprises crushing the colonized substrate and forming into the preferred form or printed scaffold for re- growing the mycelium hyphae network / injecting the colonized substrate in the form or printed scaffold using Fiber Injection Molding (FIM) and / or 3D printing. Incorporating FIM into the production of mycelium-based materials enhances both accuracy and efficiency of the manufacturing process. This technique allows for controlled variation in fiber distribution and density across different regions of the material, optimizing the properties of the final product. An example application is the production of three-dimensional forms, such as packaging, insulation materials and furniture elements where precise fiber placement improves both structural and insulation performance. This will be described in more detail below, e.g. with reference to Figures 4A-F and Figures 12A-B.

[0120] At 116, different options include dense material production and lightweight material production.

[0121] Dense material production according to an example embodiment.

[0122] Pressure 117 comprises applying pressure on the mycelium after initial reformation of the network in the mold, but before final curing, to increase density and reduce porosity.

[0123] Optionally, stacking 118 comprises stacking the modular composites after growing to weld them biologically through mycelium growth for additional days.

[0124] Optionally, pressure removal and skin development 120 comprises releasing the pressure from the mycelium composite and removing the form at the same time for further development of mycelium skin on the outer surface.

[0125] Lightweight material production according to an example embodiment.

[0126] Optionally, stacking 124 comprises stacking the modular composites after growing to weld them biologically through mycelium growth for additional days.

[0127] Optionally, skin development 126 comprises form removal for additional (e.g. 1 to 5 days) for more chitinous skin development around the composite in the right environment. The environment depends on the type of mycelium and substrate used, but may be in a temperature range of 20C to 30C, relative humidity of 60% to 99%, time between 3 to 10 days.

[0128] Next, in either one of the dense or lightweight production process, following any of 117, 118, 120, 124, or 126, dry or wet cementation can be applied.

[0129] Wet cementation according to an example embodiment

[0130] Cementation 200 comprises deep wet the mycelium brick into the cement and cure it in oven for termination of the growth and cementation inside and on the mycelium (mycelium humidity provides the water for cementation process) until the humidity of the composite is preferably less than 10%. In example embodiment, a temperature between 45C to 85C depending on the type of mycelium strain and cement type may be used, noting that the cementation 200 could also be initially done in room environment to avoid shrinkage and later transferred to oven with given temperatures. Similar to the curing stages, this step could also be expedited in temperature above 85C. Dry cementation according to an example embodiment

[0131] Curing 202 comprises drying the mycelium composite in specific temperature for termination of the growth until the humidity of the composite is preferably less than 10%, e.g. under temperature range of 45C to 85C.

[0132] At 204, cement is mixed with right amount of water (i.e. specified water to cement ratio).

[0133] Cementation 206 inside and on mycelium brick surface comprises coat / inject / dip mycelium brick into the cement mixture and cure it in RT or inside oven until dry. In example embodiment, a temperature between 45C to 85C depending on the type of mycelium strain and cement type may be used, noting that the cementation 200 could also be initially done in room environment to avoid shrinkage and later transferred to oven with given temperatures. Similar to the curing stages, this step could also be expedited in temperature above 85C.

[0134] Preferably, the cement used in such example embodiments is re-cycled from a waste or surplus of other industrial processes, which can improve sustainability.

[0135] In one embodiment, a method of fabricating a mycelium-based product comprises the steps of providing a substrate; inoculating the substrate with mycelium; growing the mycelium on the substrate in a form for the product; and curing the grown mycelium for termination of growth; wherein the method comprises cementation of the product before, as part of, or after the curing.

[0136] The cementation may comprise deep wetting the grown mycelium in cement followed by the curing. The deep wetting may be performed at room temperature or at elevated temperatures.

[0137] The cementation may comprise applying cement in a liquid form to the grown mycelium after curing. The method may further comprise curing the grown mycelium with the cement applied at room temperature of at elevated temperatures.

[0138] The cementation may use recycled cement.

[0139] In one embodiment, a mycelium-based product, fabricated using the method according to embodiment described above is provided. In the processes according to example embodiments described with reference to Figures 1 and 2, if the scaffold or forms are biological or biocompatible such as textile, wood veneer, wood box, and hydrogels, removal of the scaffold is not required as the mycelium would digest the form or scaffold and bind to it to form. The biological or biocompatible scaffolding system according to example embodiments will not only reduce the need for plastic-based forms but also acts as additional reinforcement and nutrition for improvement of mechanical and physical properties of the composite. In both Figures 1 and 2, 114,124 and 126 the mycelium could be overlayed in middle, bottom and top with natural fibers, wood or veneer, allowing these materials to co-grow with the composite and thereby enhance performance. This is particularly advantageous when the products illustrated in Figures 1 and 2 are going to be pressed to high density panels as shown in Figures 3-6 and 8 to 9. Alternatively, the products of Figures 1 and 2 could be pressed hot / cold with 3 -dimensional shaped veneer on the surface of pre-grown mycelium composite before or after growth termination. This can e.g. provide improved acoustic properties, as well as enhanced durability, aesthetic and overall performance.

[0140] Figure 11 shows a schematic drawing illustrating a portion of the production process related to the veneer 1100 attachment to light-weight mycelium composite 1102 on a base 1103, according to an example embodiment. Specifically, a support plate 1104 with a 3-dimensioal stamp 1106 is hot / cold pressed, i.e. under pressure applied to the support platel l04 / stamp 1106 onto the surface of the mycelium composite 1102, prior to termination of growth of the mycelium composite 1102, which can have the advantage of not requiring an additional adhesive for bonding of the veneer 100 to the mycelium composite 1104, if the pre-grown composite is dried for termination of growth, additional binder matrix might be necessary to enhance binding between veneer and the mycelium composite. It is noted that in another example embodiments, the stamp 1106 can be flat for flat veneer attachment to the mycelium composite 1104.

[0141] In one embodiment, a method of fabricating a mycelium-based product comprises the steps of providing a substrate; inoculating the substrate with mycelium; growing the mycelium on the substrate in a form for the product; and curing the grown mycelium for termination of growth; wherein the method comprises attaching a veneer layer to a surface of the grown mycelium prior to termination of growth, preferably without requiring an additional binder material, or attaching a veneer layer to a surface of the grown mycelium after termination of growth using an additional binder material.

[0142] The method may comprise attaching the veneer layer to the surface using a stamp.

[0143] The stamp may comprise a substantially flat stamp surface.

[0144] The stamp may comprise a substantially textured surface for imprinting a 3-dimesnional structure on the surface of the grown mycelium.

[0145] The attaching of the veneer layer may be performed as part of the curing. The curing may be performed under pressure at room temperature of at elevated pressures.

[0146] In one embodiment, a mycelium-based product comprises grown mycelium; and a veneer layer attached to the surface of the grown mycelium.

[0147] The veneer layer may have a substantially flat outer surface.

[0148] The veneer layer may have a substantially textured outer surface.

[0149] The product may be fabricated using the method according to the embodiment described above. The products produced as illustrated in Figures 1 and 2 can be combined in hybrid forms with those shown in Figures 3 to 9. This approach enables greater flexibility in utilizing mycelium technology across various applications, taking advantage of the diverse properties of mycelium-based materials for optimal performance and adaptability. To produce medium to high-density mycelium -based composite boards according to example embodiments, several techniques are presented in the following Figures 3-6 and Figures 8 to 9. With reference generally to Figure 3A, similar process as explained earlier above with reference to Figures 1 and 2 are followed until the forming process. To produce high density mycelium-based composite materials with properties similar to Plywood, MDF and chipboard panels, the crushed colonized substrate will be injected into modular shape with interlocking mechanism and the growth process of the mycelium is then continued until the chitinous skin develops around the modular shape, with or without adding an extra source of binder(s). Thereafter the form will be removed and an additional growth period of e.g. 1 to 5 days will be considered for further development of the skin. Once the skin is developed, the composite panel will be dried at certain temperature to reduce the humidity of the panel to 10% or less. To produce the high-density mycelium composite elements the modular mycelium composite panels will be laid down in certain direction depending on the interlocking mechanism and will be optionally overlaid with alternate layers of pure mycelium binder / other adhesive matrixes and / or oriented natural fibers. Thereafter, the layered matrix will be placed under a heat press compression-forming machine. A pressure of minimum 1 MPa and a temperature of minimum 100C will be applied for at least 5 minutes, according to an example embodiment.

[0150] It is noted that in a preferred embodiment, pressing can be done partially under heat and partially under cold in exchangeable orders to reduce the energy required, time and improve bonding. In some embodiments, the hot pressing is performed at a temperature between 100 °C and 200 °C under a pressure of at least 1 MPa for 1-3 minutes (this can be longer given size and geometry), followed by a cold pressing step at ambient temperature (15-30 °C) or cooled plates (0-15 °C) at the same or higher pressure for 1-2 minutes (this can be longer given size and geometry). The alternating hot / cold pressing sequence can accelerate binder development and structural stabilization: during the hot step, elevated temperature softens fibers, drives moisture evaporation, and activates binding reactions, while during the subsequent cold step, vapor in pores condenses releasing latent heat and improving inward heat transfer, at the same time reducing internal stresses and stabilizing nascent bonds. This combined effect allows faster cycle times by promoting more uniform heat distribution, controlled moisture management, and efficient bond setting, such that total pressing time can be reduced while achieving equivalent or improved mechanical properties compared to continuous hot pressing. In experiments it was found that that with this approach one can reduce the press time to 2 min according to a non-limiting example embodiment.

[0151] In one embodiment, a method of fabricating a mycelium-based composite product comprises the steps of providing a mycelium-based material comprising a mycelium-colonized substrate, the material being either (i) a crushed fibrous substrate injected into a form, or (ii) a substrate grown directly in a form; and curing the mycelium-based material by alternating hot and cold pressing steps. The hot pressing is performed at a temperature between about 100 °C and 200 °C under a pressure of about 1 MPa or higher, the hot pressing may be applied for about 1-10 minutes, preferably about 1 to 3 minutes.

[0152] The cold pressing may be performed at a temperature between about 0 °C and 30 °C under a pressure of about 1 MPa or higher. The cold pressing is applied for about 1-10 minutes, preferably about 1-2 minutes.

[0153] The alternating hot and cold pressing may reduce the total curing time to about 2 minutes.

[0154] The alternating hot and cold pressing sequence may accelerate binder development, promotes internal condensation of water vapor, and stabilizes bonding of the mycelium material.

[0155] In one embodiment, a mycelium-based composite product fabricated by the method according to the above embodiment is provided.

[0156] The product may exhibit improved bonding and mechanical properties as a result of the alternating hot and cold pressing.

[0157] Figures 3C-E show photographs illustrating parts of the production process of dense mycelium materials according to example embodiments, Figure 3C: using mycelium materials 350 pre-grown in shape, Figure 3D: using several pieces 352-354 interlocked or beside each other, Figure 3E: final element 356 after producing with either technique.

[0158] To reduce the time required for pressing the panels and for faster heat transfer the composite could be optionally pre-heated in an oven with preferably similar temperature to pressing condition for at least 30 min to several hours. This step has shown significant difference in reduction of pressing time from at least 15 min to 5 min or lower which is very important for industries. Additionally releasing the pressure intermittently during the compression would significantly reduce the chance of delamination after final pressure release, this step is especially important when desired final density of the panel is more than 600 kg / m3. Figure 3F shows such delamination (see circle 370), whereas Figure 3G shows the absence of delamination (see circle 372) with releasing the pressure intermittently during the compression, according to a preferred embodiment.

[0159] In one embodiment, a method of fabricating a mycelium-based product comprises the steps of providing a substrate; inoculating the substrate with mycelium; growing the mycelium on the substrate in a form for the product; and curing the grown mycelium for termination of growth; wherein the method comprises intermittent application of pressure during the growing of the mycelium prior to the curing.

[0160] The method may comprise determining timing of the intermittent application of pressure based on a visual assessment of progress of the growth of the mycelium.

[0161] The intermittent pressure may be in a range from about 0.2 MPa to more than 2 MPa for a sample with surface area of 2500 mm2. The growing may be performed in a temperature range of about 20°C-30 °C.

[0162] The curing for termination of growth may comprise subjecting the grown mycelium to a temperature in the range of 45°C-85°C.

[0163] In one embodiment, a mycelium-based product fabricated using the method according to the abovementioned embodiment is provided.

[0164] After pressing the panels, depending on the application of the boards, additional coatings may be applied to prevent any UV, insects, moisture, and fire related damages.

[0165] Further modification of the high-density mycelium-based composite materials for high strengths applications can be carried out according to example embodiments by reinforcing the top and bottom layers of the composite with natural fibers and / or fiber-based composite board (e.g. bamboo composite) and / or natural timber and / or engineered timber products (e.g. glue laminated timber) and / or veneer (e.g. wood veneer) by using an adhesive matrix. At the next step, adequate amount of pressure with or without heat will be applied to the overall layered matrix to create a hybrid system. The final product according to an example embodiment has properties similar to that of MDF, Plywood and can be used in variety of applications such as flooring, wall panels, and etc, e.g. flexural strength from 5 to 30MPa, elastic modulus in bending from 2 to 10 GPa, compressive strength from 2 to 20 MPa, and tensile strength from 1 to 15 MPa may be achieved. Similar to other example embodiments described above, the final product can be coated or left non-coated depending on the application.

[0166] In more detail, Figure 3A shows board production with the focus on forming, according to various example embodiments.

[0167] Colonized substrate collection 300 comprises commercially cultivated mushroom colonized substrate collection from farmers / in house production before harvesting fruit / after harvesting fruit. Colonization of fibers could also directly happen in forming 302. In other words, colonized substrate collection 300 according to this example embodiment constitutes a re- using / re-cycling from production by farmers / in house, including after harvesting fruit for other purposes / processes.

[0168] Optionally, forming 302 comprises crushing the colonized substrate and forming into the preferred form / printed scaffold for re- growing the mycelium hyphae network / injecting the colonized substrate in the form or printed scaffold using Fiber Injection Molding (FIM) and / or 3D printing.

[0169] Optionally, following 300 or 302, skin development 304 comprises plastic bag / form removal for e.g. 1-5 days for more chitinous skin development around the baglogs / modular panels in right environment. Following any of 300, 302 or 304, curing 306 comprises drying the baglog / modular panels in specific temperature for termination of the growth until the humidity of the composite is preferably less than 10%, e.g. under temperature range of 45C to 85C.

[0170] In one embodiment, the process can be terminated at storage 308, i.e. keeping the dried modular panels / bags in a dried ventilated environment for future processing for different application.

[0171] Otherwise, following 306, heat and pressure 310 comprises applying a pressure of at least 1 MPa with or without vacuum at Temperature not exceeding 200°C. Optionally, 310 is preceded by layering 312 comprises overlaying the modular mycelium panels with / without oriented natural fibers / veneers. Vacuum can help to avoid bubbles forming in the board which would result in delamination.

[0172] Pressure removal and cure 314 comprises releasing the pressure and optionally curing the pressed board in a post-curing oven, e.g. in temperature range of 35C to 50C.

[0173] Next, if additional humidity, UV, mite and / or fire retardancy are required, the relevant coating(s) are applied at 316 prior to the material being ready for use. If not, the material is ready for use at 318.

[0174] In order to reduce the production time, carbon emission and cost as well as large-scale production feasibility of dense mycelium panels, a production technique according to other example embodiments will now be described with reference to Figures 4A-F.

[0175] In more detail, Figure 4A shows board production with the focus on crushing the substrate according to various example embodiments.

[0176] Colonized substrate collection 400 comprises commercially cultivated mushroom colonized substrate collection from farmers / in house production before / after harvesting fruit.

[0177] Processing and curing 402 comprises crushing the colonized substrate and drying it (e.g. under temperature range of 45C to 85C) for easier storage and transportation and a significant reduction in production cost.

[0178] Optionally, layering 404 comprises overlaying the crushed mycelium with oriented fibers / veneers as reinforcement.

[0179] Following 402 or 404, heat and pressure 406 comprises injecting or transferring the crushed colonized substrate in to the desired form for pressing with a pressure of at least 1 MPa with or without vacuum and a temperature not exceeding 200°C. Injection of fibers into the desired geometry prior to production would also allow optimized distribution of fibers with varying density in to the form [E. Foerster and M. Heinl, “Device and method for manufacturing moulded parts from fibrous material,” EP2305869 (Al), EP EP20100010798 20100927, Apr 6, 2011; E. Forster, “METHOD AND DEVICE FOR PRODUCING MOULDED PARTS MADE OF FIBRE MATERIAL,” EP2903800 (Al), EP EP20130780090 20131001, Aug 12, 2015; E. Foerster, “METHOD AND DEVICE FOR PRODUCING THREE-DIMENSIONAL MOLDED PARTS AND CORRESPONDING MOLDED PART,” EP1631441 (Al), EP EP20040725326 20040402, Mar 8, 2006],

[0180] Utilizing extensive fibrous resources across varying size ranges for the production of mycelium-based products / materials according to example embodiments can also allow for the optimization of fiber size distribution. This optimization is advantageous, as the distribution of fiber sizes in the composite can significantly impact the final density, porosity, and mechanical performance. Additionally, when using a single type of fiber, sieving and / or milling the fibers before colonizing them with mycelium can further enhance fiber size distribution. This process influences the density of the mycelium network and the material's behavior during forming and pressing processes. In example embodiments of the present invention, the mechanical properties of the produced composite / product can be tailored with respect to the final application.

[0181] Figures 4B-D show photographs illustrating the fibers 450 inoculated with mycelium injected into the form 452 using a combination of FIM and heat-press technique. Figure 4E shows a photograph of a three-dimensional dense mycelium board 454 produced with such a combination of fiber injection molding and heat-press technique, according to an example embodiment, produced with varying density along the edge for improvement of stiffness. For comparison, Figure 4F shows a photograph of a similar board 456 produced without higher density of edges, which shows breakage of the edges.

[0182] Intermittent release of pressure during the production can preferably avoid delamination and destruction of such elements as explained above with reference to Figures 3F and G.

[0183] Pre-Heating of fibers prior to injection and heat-press would also reduce the required time for production of such elements this is applicable to example embodiments presented in Figures 3-6 and 8 to 9.

[0184] Partial pressing the fibers in heat followed by cold pressing or vice-versa would also significantly reduce the press time and mechanical performance of the final product.

[0185] Pressure removal and cure 408 comprises releasing the pressure and optionally curing the pressed board in a post-curing oven, e.g. in temperature range of 35C to 50C.

[0186] Next, if additional humidity, UV, mite and / or fire retardancy are required, the relevant coating(s) are applied at 410 prior to the material being ready for use. If not, the material is ready for use at 412.

[0187] It is noted that the process described above typically results in a dense mycelium-based product such as a seat plate 1200 for a chair shown in Figure 12A, exhibiting varying density along edges (such as circled area 1202), resulting from differences in the combination of pressure and heat during stages of production with a total processing time of, for example, less than 5 minutes. In another example embodiment, a lightweight mycelium-based product such as shell 1210 in Figure 12B, with locally increased density in sensitive or thin corner regions (for example circled area 1212), can be produced by allowing post-growth in a bottom mold or form with a corresponding top mold or stamp disposed at a certain height above the height of the initially injected fibers inoculated with mycelium, preferably with higher amounts injected at portions requiring increased density such as in the circled area 1212, over several days without application of heat, the growth thus filling the gap between the bottom mold or form and the top mold or stamp.

[0188] In one example embodiment, a method of fabricating a mycelium-based product comprising the steps of injecting a fibrous material comprising crushed mycelium colonized substrate material into a form for the product; and curing the fibrous material in the form; wherein the curing comprises at least one of applying heat, applying pressure, or allowing growth of the mycelium colonized substrate material.

[0189] The injecting of the fibrous material and / or the curing may be performed such that a density of the fibrous material in the fabricated product varies across the fabricated product.

[0190] The injecting of the fibrous material may be performed such that different amounts of the fibrous material are injected to a first plurality of locations in the form, and the curing comprises applying pressure in a uniform way to the first plurality of locations such that the fabricated product exhibits a substantially constant thickness across the first plurality of locations.

[0191] The injecting of the fibrous material may be performed such that substantially the same amounts of the fibrous material are injected to a second plurality of locations in the form and the curing comprises applying pressure in a non-uniform way to the second plurality of locations such that the fabricated product exhibits varying thicknesses across the second plurality of locations.

[0192] The injecting of the fibrous material may be performed such that different amounts of the fibrous material are injected to a first plurality of locations in the form, and the curing comprises growth of the mycelium in the form. A counter-form may be provided, the counter-form together with the form defining a shape of the product for guiding the growth of the mycelium into the shape of the product.

[0193] A fiber size of the fibrous material may be varied such that the fabricated product exhibits a fiber size distribution across the fabricated product.

[0194] The curing may comprise intermitted release of pressure on the fibrous material during curing.

[0195] The curing may comprise heating the fibrous material for assisting the curing

[0196] In one embodiment, a mycelium-based product comprises a cured fibrous material comprising crushed mycelium colonized substrate material cured in a form for the product.

[0197] A density of the fibrous material in the product may vary across the product. The product may comprise different amounts of the fibrous material at a first plurality of locations in the product and the product exhibits a substantially constant thickness across the first plurality of locations.

[0198] The product may comprise substantially the same amounts of the fibrous material at a second plurality of locations in the product and the product exhibits varying thicknesses across the second plurality of locations.

[0199] The product may comprise different amounts of the fibrous material at a first plurality of locations in the product, and the product comprises mycelium grown from the fibrous material.

[0200] The product may exhibit a fiber size distribution across the product.

[0201] The product may be fabricated by the method according to the embodiment described above.

[0202] It is noted that the varying density may be achieved in example embodiments by i) injecting the fiber in different amount to different locations of the mold / form and then apply a substantially uniform pressure during pressuring yielding a final product with a uniform final thickness and varying densities along the form, ii) injecting the fiber to substantially the same distribution and amount in the mold / form and then applying a varying pressure profile across the mold / form during pressuring. In ii), the thickness of the resulting product may vary according to the pressure profile, which may be less desirable in some applications. In other example embodiments, i) and ii) may be combined, to achieve both varying density and control over the final product’s thickness and stiffness.

[0203] In another process according to an example embodiment, and with reference generally to Figure 5, mycelium is grown in bulk forms in a mushroom growing facility and the colonized substrate would be processed in 3 different ways for production of composites / products. In the first process the colonized substrate is crushed and then injected (e.g. using FIM) in to the modular form for reconnecting the mycelium network with or without reinforcement layers and after drying the regrown mycelium, it can be reinforced again followed by heat and pressure for development of the composite / product, similar to the process described with reference to Figures 4A-F above. In a second process the bulk colonized substrate is crushed and cured for future use. In the third process, the bulk colonized substrate is not crushed. Instead, it is cut to layers followed by optional further growing the interrupted network with or without layers of reinforcement. After drying the layers, additional reinforcement can be done followed by heat and pressure into the right form for development of the composite / product.

[0204] The bulk material can also be cut into the desired shape for the production of lightweight mycelium materials, as illustrated in Figures 1 and 2. This approach according to example embodiments can eliminate the need to grow the mycelium directly into specific forms, streamlining the manufacturing process and enhancing flexibility in production. In more detail, Figure 5 shows board production with the focus on bulk production of the substrate, according to various example embodiments.

[0205] Bulk growing 500 comprises bulk colonizing the growth substrate with commercially cultivated mushroom species, for example in containers, trays, or growth rooms, without the limitations of individual bags or molds. This enables large-scale colonization with reduced handling, lower production cost, and higher efficiency. Bulk growing also allows flexible downstream processing, since the grown mass can be cut, crushed, or re-shaped into various forms depending on the desired application.

[0206] Process path (1)

[0207] Processing 502 comprises crushing the colonized substrate.

[0208] Optionally, re-establishing the mycelium network 504 comprises injecting the crushed mycelium to modular trays for reconnecting the mycelium network with or without fibers as reinforcement.

[0209] Optionally, layering 506 comprises overlaying the modular mycelium with oriented fibers / veneers.

[0210] Following any of 502, 504 or 506, curing 508 comprises drying the crushed sub str ate / r egrown substrate until the humidity of the composite is preferably less than 10%.

[0211] Process path (2)

[0212] Processing and curing 510 comprises crushing the colonized substrate and drying it (e.g. under temperature range of 45C to 85C) for easier storage and transportation. Process path (2) is the preferred pathway due to its feasibility, efficiency, and cost-effectiveness in production. Optionally, layering 506 can be performed between 510 and 514.

[0213] Process path (3)

[0214] Cutting 512 comprises cutting the bulk colonized substrate into desired size and shape, followed by curing 508

[0215] Optionally, following 512, skin development / self-healing comprises letting the desired shape to self-heal and develop the outer skin with or without fibers as reinforcement prior to pressing, prior to curing 508. Optionally, layering 506 can be performed between 512 and 508.

[0216] In all processes (1), (2) and (3), heat and pressure 514 comprises injecting or transferring the crushed colonized substrate in to the desired shape for pressing with a pressure of at least 1 MPa with or without vacuum and a temperature not exceeding 200°C. (add fiber preheating and hot-cold pressing) Pressure removal and cure 516 comprises intermittent releasing of the pressure and optional curing the pressed board in a post-curing oven, e.g. in temperature range of 35C to 50C. (add active curing)

[0217] Next, if additional humidity, UV, mite and / or fire retardancy are required, the relevant coating(s) are applied at 518 prior to the material being ready for use. If not, the material is ready for use at 520.

[0218] Figure 6 shows another production flowchart illustrating a modified process of Figure 3, according to example embodiments for fabricating a dense mycelium board, including usage of binder matrixes for attachment of mycelium layers prior to pressing and / or reinforcing the top, middle and bottom layers of the dense mycelium board with natural fibers and / or fiberbased composite board (e.g. bamboo composite) and / or natural timber and / or engineered timber products (e.g. glue laminated timber) and / or using synthetic or natural veneers (e.g. wood veneer) by using an adhesive matrix and subsequently applying adequate amount of pressure with or without heat to create a hybrid system. The final product according to such example embodiments has properties similar to that of MDF, Plywood and can be used in variety of applications such as flooring, wall panels, and etc. Similar to other example embodiments described above, the final product can be coated or left non-coated depending on the application.

[0219] In more detail, Figure 6 shows board production with focus on using binder matrix, according to various example embodiments.

[0220] Colonized substrate collection 300 comprises commercially cultivated mushroom colonized substrate collection from farmers / in house production before / after harvesting fruit.

[0221] Optionally, forming 302 comprises crushing the colonized substrate and forming in to the preferred form / printed scaffold for re- growing the mycelium hyphae network / injecting the colonized substrate in the form or printed scaffold using Fiber Injection Molding (FIM) and / or 3D printing.

[0222] Optionally, following 300 or 302, skin development 304 comprises plastic bag / form removal for e.g. 1-5 days for more chitinous skin development around the baglogs / modular panels in right environment.

[0223] Following any of 300, 302 or 304, curing 306 comprises drying the baglog / modular panels in specific temperature for termination of the growth until the humidity of the composite is preferably less than 10%, e.g. under temperature range of 55C to 85C.

[0224] In one embodiment, the process can be terminated at storage 308, i.e. keeping the dried modular panels / bags in a dried ventilated environment for future processing for different application.

[0225] Otherwise, following 306, heat and pressure 310 comprises applying a pressure of at least 1 MPa with or without vacuum at Temperature not exceeding 200°C. (add fiber pre-heating 1 and hot-cold pressing) Optionally, 310 is preceded by layering 312 comprises overlaying the modular mycelium panels with / without oriented natural fibers / veneers.

[0226] Intermittent Pressure removal and cure 314 comprises releasing the pressure and optionally curing the pressed board in a post-curing oven (or active curing), e.g. in temperature range of 35C to 50C.

[0227] If high performance application is desired, hybrid composite system 600 comprises reinforcing the top and bottom layer of the mycelium panels with bamboo composite / natural bamboo / glue-laminated timber / dense mycelium board / natural timber / fibers / veneers or as described in Figure 1 and 2 considering the growing together with mycelium using adhesive matrix.

[0228] Heat and pressure 602 comprises applying adequate amount of pressure and temperature to the hybrid system for final bonding between mycelium board and reinforcement depending on the type of bonding matrix used, e.g. a pressure from IMPa (for this ste when only binder activation is required less pressure is also possible) to 5Mpa and temperature not exceeding 200C.

[0229] Following 602, the process returns to 314,

[0230] Next, if additional humidity, UV, mite and / or fire retardancy are required, the relevant coating(s) are applied at 316 prior to the material being ready for use. If not, the material is ready for use at 318.

[0231] In a similar process according to example embodiments of the present invention, mycelium can be grown to produce a pure mycelium binder, a 100% natural adhesive. With reference generally to Figure 7, firstly liquid media or hydrogel substrate or solid substrate will be used as the substrate for the growth of the mycelium. After sterilizing the substrate, inoculation of the substrate will be carried out by using liquid inoculum or scraping mycelium from the agar plate or using solid spawn. Subsequently if the mycelium growth is in liquid culture, the mycelium will be grown in a rotary shaker and incubator at certain environmental conditions for between 3 to 15 days or more depending on the species of the mushroom used. Thereafter, mycelium pallets will be filtered from the liquid culture and cured to terminate the growth. Mycelium biomass obtained from this process will be used as additional binder in production of high-density mycelium-based composites or other fiber based commercial boards (e.g. particle board), for example as described above with reference to Figure 6. In other example embodiments, pure mycelium binder can be grown as layers on surface of hydrogel or solid substrate for 3 to 15 days or more depending on the species of mycelium used. Afterwards, Collecting the skin layers of the grown mycelium from liquid, hydrogel, or solid substrate and overlaying them for further growth, will lead to additional growth of the mycelium to form thicker layers of pure mycelium skin. The formed biomass, after drying and termination of the growth can be used as a natural binder for fabrication of high-density mycelium-based composites, for example as described above with reference to Figure 6. In more detail, Figure 7 shows pure mycelium binder production, according to various example embodiments.

[0232] Pure mycelium substrate preparation 700 comprises prepare liquid media or solidified liquid media (e.g. agar) or thin layer of solid substrate as the substrate for mycelium growth.

[0233] At 702, sterilize the substrate.

[0234] Inoculation 704 comprises introducing liquid inoculum / inoculum on hydrogel substrate / solid spawn in to the clean sterilized growth media.

[0235] Liquid medium colonization 706 comprises growing mycelium in a bioreactor in the right environment for mycelium propagation in the media, e.g. at temperature 20C to 30C with or without shaking. Using the bioreactor is the desired pathway due to it scalability.

[0236] Mycelium filtration 708 comprises separate the supernatant from mycelium biomass with filter.

[0237] In another process example, after 706, pure mycelium skin development 710 comprises transfer the colonized growing mycelium in to the right container with more surface area and exposure to cold-warm cycles (e.g. 2-8C and 20-30C, respectively) and / or to saturated CO2 environment for skin development (e.g. saturated CO2 at relative humidity of up to 99% and with CO2 concentration of 20,000 to 100,000 ppm).

[0238] Skin overlay 712 comprises overlay few layers of growing mycelium skin and re-grow them on a liquid / solidified liquid media / thin solid substrate to form thicker layers of pure mycelium.

[0239] If the growth is done on solidified liquid media, after inoculation 704, pure mycelium skin development 714 comprises grow the mycelium on solidified liquid media to develop pure mycelium skin layer on the surface of the liquid in the right environment and encourage more skin development through cold- warm cycles (e.g. 2-8C and 20-30C, respectively) and / or CO2 saturated environment (e.g. saturated CO2 at relative humidity of up to 99% and with CO2 concentration of 20,000 to 100,000 ppm).

[0240] If the growth in done on thin solid substrate, after inoculation 704, pure mycelium skin development 716 comprises growing the mycelium skin on thin layer of solid substrate and encourage skin development through cold-warm cycles (e.g. 2-8C and 20-30C, respectively) and / or CO2 saturated environment, e.g. saturated CO2 at relative humidity of up to 99% and with CO2 concentration of 20,000 to 100,000 ppm (e.g. enclosed and dense substrate in a form with opening on top).

[0241] After 714 or 716, skin overlay 712 follows.

[0242] After 708 or 712, curing 718 comprises drying the mycelium biomass or skin in specific temperature for termination of the growth; e.g. under temperature range of 45C to 85C. Storage 720 comprises keeping the dried mycelium biomass / skin in a dried ventilated environment as a natural binder / as a mycelium veneer for different application within and beyond mycelium industry.

[0243] In one embodiment, a method of producing a mycelium-based binder, comprises providing a substrate; inoculating the substrate with mycelium; growing the mycelium; harvesting the grown mycelium in the form of a biomass as the mycelium-based binder; and curing the biomass to terminate growth.

[0244] The substrate may comprise a liquid medium and the biomass is obtained from liquid culture and collected as pellets following filtration of the culture.

[0245] The substrate may comprise a hydrogel or solid substrate and the biomass is obtained as one or more skin layers. The method may further comprise overlaying two or more of the skin layers to form a stack and allowing further mycelial growth to thicken the stack prior to curing.

[0246] The curing may comprise drying at a temperature between about 45 °C and 85 °C until the humidity of the biomass is below about 10%.

[0247] In one embodiment, a composite material comprises a fibrous or granular substrate selected from one or more of a group consisting of wood fibers, cellulose fibers, agricultural fibers, wood chips, husks, and straw; and a mycelium binder fabricated by a method according to the embodiments described above, wherein the mycelium binder bonds the substrate into the composite material.

[0248] The composite material may be in the form of a particleboard, fiberboard, a medium-density board, or a high-density board.

[0249] The composite material may be in the form of a chipboard, husk board, or strawboard.

[0250] The composite material may be in the form of a hybrid mycelium-based board further comprising one or more of a group consisting of a veneer layer, an engineered timber layer, a fiber-reinforced composite.

[0251] In one embodiment, a method of using the mycelium binder according to the embodiment described above as an adhesive for producing fiber-based or granular-based composite material.

[0252] The composite material may be in the form of a particleboard, fiberboard, a medium-density board, or a high-density board.

[0253] The composite material may be in the form of a chipboard, husk board, or strawboard.

[0254] The composite material may be in the form of a hybrid mycelium-based board further comprising one or more of a group consisting of a veneer layer, an engineered timber layer, a fiber-reinforced composite. In an alternative to the embodiments shown in Figure 7, a promising method for producing a binder from mycelium materials according to an example embodiment involves utilizing the waste generated from fruiting body production in farms. This waste serves as a rich source of hyphae — the long, branching, filamentous structures that form the network of mycelium. The waste can be dried, pulverized, and stored for subsequent use in mycelium material production, as well as other applications The advantage of using fruiting body waste over the process described in Figure 7 is that it requires no additional steps for production, however the end product might contain impurities which could potentially alter the binding capabilities of mycelium as a binder.

[0255] In a process similar to production of mycelium binder as described with reference to Figure 7, mycelium veneer could also be produced according to example embodiments.

[0256] With reference generally To Figure 8, in the mycelium-veneer production process according to example embodiments, colorized substrate is collected either before or after fruiting from farms or in-house production facility. The surface of the collected substrate develops a skin, which can be peeled off, or the blocks can undergo additional growing cycles with or without cold-warm cycles and CO2 saturation. The developed skin can then be detached from the block, forming a veneer that is dried to achieve a humidity level preferably below 10%. Depending on the application and desired dimensions and thickness of the veneer, the detached skin can be overlaid to provide additional binding, resulting in thicker and / or larger veneer production. The mycelium block, after the skin is detached, can be exposed to further development of new skin.

[0257] In more detail, Figure 8 shows Mycelium-veneer production, according to various example embodiments.

[0258] Mycelium block collection 800 comprises Mycelium baglogs or blocks collection from farmers / in house production before / after harvesting fruit.

[0259] Skin development 802 comprises regrowing the mycelium block for development of additional skin surface with or without exposure to cold-warm cycles (e.g. 2-8C and 20-30C, respectively) and CO2 saturation (e.g. saturated CO2 at relative humidity of up to 99% and with CO2 concentration of 20,000 to 100,000 ppm).

[0260] After 800 or 802, curing 804 comprises drying the peeled skin in specific temperature for termination of the growth until the humidity of the composite / skin is preferably less than 10%, e.g. under temperature range of 45C to 85C.

[0261] Storage 806 comprises keeping the dried pure mycelium skin (veneer) in a dried ventilated environment for further applications.

[0262] Optionally, after 802, skin detachment 808 comprises peeling off the skin from composite and recycling the inner composite by re-growing the skin layers. Skin overlay 810 comprises overlaying few layers of chitinous skin and re- growing them in the right environment for binding together and developing thicker skin, followed by curing 804. With reference generally to Figure 9, the cured skin layers can be overlaid in a specific form and subjected to high pressure and heat. This process results in the formation of a denser board with increased binding between the individual layers through the application of pressure and heat, according to example embodiments. The end result is a panel composed entirely of mycelium, for example for pressed mycelium-veneer production.

[0263] In more detail, Figure 9 shows pressed mycelium-veneer production, according to various example embodiments.

[0264] Mycelium block collection 800 comprises Mycelium baglogs or blocks collection from farmers / in house production before / after harvesting fruit.

[0265] Skin development 802 comprises regrowing the mycelium block for development of additional skin surface with or without exposure to cold-warm cycles (e.g. 2-8C and 20-30C, respectively) and CO2 saturation (e.g. saturated CO2 at relative humidity of up to 99% and with CO2 concentration of 20,000 to 100,000 ppm).

[0266] After 800 or 802, curing 804 comprises drying the peeled skin in specific temperature for termination of the growth until the humidity of the composite / skin is preferably less than 10%, e.g. under temperature range of 45C to 85C.

[0267] Optionally, after 802, skin detachment 808 comprises peeling off the skin from composite and recycling the inner composite by re-growing the skin layers. Skin overlay 810 comprises overlaying few layers of chitinous skin and re- growing them in the right environment for binding together and developing thicker skin, followed by curing 804.

[0268] Following 804, heat and pressure 900 comprises overlaying detached skins and connect them together through applying a pressure of at least 1 Mpa with or without vacuum at temperature not exceeding 200°C. (combination of partial heat and cold pressing and adding veneer preheating)

[0269] Intermittent Pressure removal and cure 902 comprises releasing the pressure and optionally curing the pressed veneer in a post-curing oven, e.g. in temperature range of 35C to 50C. (add active curing).

[0270] In one embodiment, a method of producing a mycelium-based veneer layer comprises the steps of providing a substrate; inoculating the substrate with mycelium; growing the mycelium; harvesting the grown mycelium in the form of one or more skin layers as the mycelium-based veneer layer; and curing the veneer layer to terminate growth.

[0271] The substrate may comprise a hydrogel or solid substrate.

[0272] The method may further comprise overlaying two or more of the skin layers to form a stack and allowing further mycelial growth to thicken the stack prior to curing.

[0273] The curing may comprise drying at a temperature between about 45 °C and 85 °C until the humidity of the veneer layer is below about 10%. In one embodiment, a composite material comprises a fibrous or granular substrate selected from one or more of a group consisting of wood fibers, cellulose fibers, agricultural fibers, wood chips, husks, and straw; and a mycelium veneer fabricated by a method according to the embodiment described above; wherein the mycelium veneer covers a surface of composite material.

[0274] The composite material may be in the form of a particleboard, fiberboard, a medium-density board, or a high-density board.

[0275] The composite material may be in the form of a chipboard, husk board, or strawboard.

[0276] The composite material may be in the form of a hybrid mycelium-based board further comprising one or more of a group consisting of a veneer layer, an engineered timber layer, a fiber-reinforced composite.

[0277] The production of composites / products according to example embodiments, as described in Figures 3-6 and 8-9, can be carried out without pre-curing of the composite.. Additionally, it should be taken into consideration that composites / products according to example embodiments can also be produced through cold pressing. However, panels produced solely through cold pressing may not possess the same level of strength as those exposed to both heat and pressure. Heat preferably causes fluidity in chemical composition of both substrate and mycelium allowing for better penetration and binding, additionally, heat can promote chemical reactions such as cross-linking in these natural binders, which leads to the formation of stronger and more durable bonds between the mycelium and the substrate particles. Heat also removes the trapped moisture in the mycelium and substrate which would otherwise weaken the bond. In all the processes explaining the production process of pressed mycelium panels (Figures 3-6 and Figures 8-9), the pressing stage could also be performed prior to drying the material, however this would typically increase the required time and temperature needed for production of final product.

[0278] With reference generally to Figure 10, the complete supply chain of mycelium materials according to example embodiments is shown. In one scenario, waste materials from furniture factories, agricultural or horticultural farms, and other industries dealing with wood or organic fibers are collected and sent to a nearby collection center, located close to the mushroom farm or substrate production center. The selected substrates are then colonized with specific fungal species, and the resulting colonized substrate is either in block form or crushed before being sent to the composite / product production center.

[0279] In more detail, Figure 10 shows Supply chain and business model of mycelium-based composite materials / products production, according to various example embodiments.

[0280] At 1000, any factory or individual dealing with wood or organic fibers, at 1002, Agri cultural / horti cultural farms and at 1004 Furniture factories, provide waste to waste collection center 1006.

[0281] Waste collection center 1006 provides waste to mushroom farms 1008. Mushroom farms 1008 prepare colonized mycelium substrate at 1010 and fruiting bodies at 1012. Using the leftover mycelium substrate at 1010 provides a return to 1008.

[0282] The chain ends at the customers 1012.

[0283] From 1010, substrate is also provided to Mycelium composite production centers 1014 for various customers 1016. A return of Mycelium materials after end of life to the waste collection center 1006 is also provided. For fruiting body, the customers 1013 are mainly buying the fruits, for food or medical production, but the customers 1016 are mainly from furniture, construction or automobile industry where they use the composite mycelium but not the fruit.

[0284] If, based on the example embodiments described above with reference to Figures 1 to 9, drying of the colonized substrate is required before further processing, it is preferable to perform this step at the substrate production facility. This ensures avoidance of contamination and minimizes the weight and space needed for transporting the colonized substrate to the composite / product production center. At the production center, the colonized substrate is processed according to the example embodiments described with reference to Figures 1 to 9. The resulting composite / product is then distributed to customers across various industries.

[0285] As part of the circular business model according to example embodiments, after the end of life of the mycelium materials and other organic waste from customers, these materials are transferred to a dedicated waste collection center. Here, they are supplemented and colonized again with mycelium for subsequent use in composite / product production according to example embodiments.

[0286] The waste of the mushroom farm can be collected after harvesting the fruits followed by drying the harvested colonized substrate and transferring them to composite / product production center for further processing according to example embodiments as described with reference to Figures 1 to 9. The remaining steps of the process according to such embodiments are similar to the example embodiments described above with reference to Figures 1 to 9.

[0287] These steps as shown in Figure 10, i.e. regional modular nodes, dual product streams, and particularly recolonization of end-of-life composites, in combination form a unique supplychain architecture. When further combined with the various techniques described according to example embodiments of the present invention, this can form a holistic, patentable system.

[0288] Embodiments of the present invention aim to address one or more of three main challenges;

[0289] 1- Waste generated due to the use of non-environmentally friendly products such as plastics, binders and adhesives which impede the recycling and / or upcycling of such products.

[0290] 2- Deforestation due to excessive demand for timber-based products which has led to cutting more trees faster than the rate of re-forestation globally. 3- The carbon footprint of only construction industry has shown to be responsible for about 40% of the global greenhouse gas emissions which is mainly driven by the use of synthetic, energy-intensive and non-recyclable products dominated by cements, concrete and plastics.

[0291] Industrial applications of example embodiments of the present invention include, but are not limited to, insulation, packaging, automotive, furniture, wood-based panels industry, construction of interior design, furniture parts, table tops, partition wall, kitchen cabinets, shelf, false ceilings.

[0292] It will be appreciated by a person skilled in the art that numerous variations and / or modifications may be made to the present invention as shown in the specific embodiments without departing from the spirit or scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all respects to be illustrative and not restrictive. Also, the invention includes any combination of features described for different embodiments, including in the summary section, even if the feature or combination of features is not explicitly specified in the claims or the detailed description of the present embodiments.

[0293] In general, in the following claims, the terms used should not be construed to limit the systems and methods to the specific embodiments disclosed in the specification and the claims, but should be construed to include all processing systems that operate under the claims. Accordingly, the systems and methods are not limited by the disclosure, but instead the scope of the systems and methods is to be determined entirely by the claims.

[0294] Unless the context clearly requires otherwise, throughout the description and the claims, the words "comprise," "comprising," and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in a sense of "including, but not limited to." Words using the singular or plural number also include the plural or singular number respectively. Additionally, the words "herein," "hereunder," "above," "below," and words of similar import refer to this application as a whole and not to any particular portions of this application. When the word "or" is used in reference to a list of two or more items, that word covers all of the following interpretations of the word: any of the items in the list, all of the items in the list and any combination of the items in the list.

Claims

CLAIMS1. A method of fabricating a mycelium-based product comprising the steps of: injecting a fibrous material comprising crushed mycelium colonized substrate material into a form for the product; and curing the fibrous material in the form; wherein the curing comprises at least one of applying heat, applying pressure, or allowing growth of the mycelium colonized substrate material.

2. The method of claim 1, wherein the injecting of the fibrous material and / or the curing is performed such that a density of the fibrous material in the fabricated product varies across the fabricated product.

3. The method of claims 1 or 2, wherein the injecting of the fibrous material is performed such that different amounts of the fibrous material are injected to a first plurality of locations in the form, and the curing comprises applying pressure in a uniform way to the first plurality of locations such that the fabricated product exhibits a substantially constant thickness across the first plurality of locations.

4. The method of any one of claims 1 to 3, wherein the injecting of the fibrous material is performed such that substantially the same amounts of the fibrous material are injected to a second plurality of locations in the form and the curing comprises applying pressure in a non- uniform way to the second plurality of locations such that the fabricated product exhibits varying thicknesses across the second plurality of locations.

5. The method of claims 1 or 2, wherein the injecting of the fibrous material is performed such that different amounts of the fibrous material are injected to a first plurality of locations in the form, and the curing comprises growth of the mycelium in the form.

6. The method of claim 5, wherein a counter-form is provided, the counter-form together with the form defining a shape of the product for guiding the growth of the mycelium into the shape of the product.

7. The method of any one of the preceding claims, wherein a fiber size of the fibrous material is varied such that the fabricated product exhibits a fiber size distribution across the fabricated product.

8. The method of any one of the preceding claims, wherein the curing comprises intermitted release of pressure on the fibrous material during curing.

9. The method of any one of the preceding claims, wherein the curing comprises heating the fibrous material for assisting the curing10. A mycelium-based product comprising a cured fibrous material comprising crushed mycelium colonized substrate material cured in a form for the product.

11. The product of claim 10, wherein a density of the fibrous material in the product varies across the product.

12. The product of claims 10 or 11, comprising different amounts of the fibrous material at a first plurality of locations in the product and the product exhibits a substantially constant thickness across the first plurality of locations.

13. The product of any one of claims 10 to 12, comprising substantially the same amounts of the fibrous material at a second plurality of locations in the product and the product exhibits varying thicknesses across the second plurality of locations.

14. The product of claims 10 or 11, comprising different amounts of the fibrous material at a first plurality of locations in the product, and the product comprises mycelium grown from the fibrous material.

15. The product of any one of claims 10 to 14, wherein the product exhibits a fiber size distribution across the product.

16. The product any one of claims 10 to 15, fabricated by the method of any one of claims 1 to 9.

17. A method of fabricating a mycelium-based product comprising the steps of: providing a substrate; inoculating the substrate with mycelium; growing the mycelium on the substrate in a form for the product; and curing the grown mycelium for termination of growth; wherein the method comprises intermittent application of pressure during the growing of the mycelium prior to the curing.

18. The method of claim 17, comprising determining timing of the intermittent application of pressure based on a visual assessment of progress of the growth of the mycelium.

19. The method of claims 17 or 18, wherein the intermittent pressure is in a range from about 0.2 MPa to more than 2 MPa for a sample with surface area of 2500 mm2.

20. The method of any one of claims 17 to 19, wherein the growing is performed in a temperature range of about 20°C-30 °C.

21. The method of any one of claims 17 to 20, wherein the curing for termination of growth comprises subjecting the grown mycelium to a temperature in the range of 45°C-85°C.

22. A mycelium-based product, fabricated using the method according to any one of claims 17 to 21.

23. A method of fabricating a mycelium-based product comprising the steps of: providing a substrate; inoculating the substrate with mycelium; growing the mycelium on the substrate in a form for the product; and curing the grown mycelium for termination of growth; wherein the method comprises cementation of the product before, as part of, or after the curing.

24. The method of claim 23, wherein the cementation comprises deep wetting the grown mycelium in cement followed by the curing.

25. The method of claim 24, wherein the deep wetting is performed at room temperature or at elevated temperatures.

26. The method of claim 23, wherein the cementation comprises applying cement in a liquid form to the grown mycelium after curing.

27. The method of claim 26, further comprising curing the grown mycelium with the cement applied at room temperature of at elevated temperatures.

28. The method of any one of claims 22 to 26, wherein the cementation uses recycled cement.

29. A mycelium-based product, fabricated using the method according to any one of claims 23 to 28.

30. A method of fabricating a mycelium-based product comprising the steps of: providing a substrate; inoculating the substrate with mycelium; growing the mycelium on the substrate in a form for the product; and curing the grown mycelium for termination of growth; wherein the method comprises attaching a veneer layer to a surface of the grown mycelium prior to termination of growth, preferably without requiring an additional binder material, or attaching a veneer layer to a surface of the grown mycelium after termination of growth using an additional binder material.

31. The method of claim 30, comprising attaching the veneer layer to the surface using a stamp.

32. The method of claim 31, wherein the stamp comprises a substantially flat stamp surface.

33. The method of claim 31, wherein the stamp comprises a substantially textured surface for imprinting a 3-dimesnional structure on the surface of the grown mycelium.

34. The method of any one of claims 30 to 33, wherein the attaching of the veneer layer is performed as part of the curing.

35. The method of claim 34, wherein the curing is performed under pressure at room temperature of at elevated pressures.

36. A mycelium-based product comprising: grown mycelium; and a veneer layer attached to the surface of the grown mycelium.

37. The product of claim 36, wherein veneer layer has a substantially flat outer surface.

38. The product of claim 36, wherein the veneer layer has a substantially textured outer surface.

39. The product of any one of claims 36 to 38, fabricated using the method of any one of claims 30 to 35.

40. A method of fabricating a mycelium-based product comprising the steps of: providing a substrate; inoculating the substrate with mycelium; growing the mycelium on the substrate in a form for the product; and curing the grown mycelium for termination of growth; wherein the method comprises intermittent release of a pressure applied during the curing.

41. The method of claims 40, wherein the pressure during curing is about 1 MPa or higher.

42. The method of claims 40 or 41, wherein the curing is performed in a temperature range of about 100 °C or higher.

43. A mycelium-based product, fabricated using the method according to any one of claims 40 to 42.

44. A method of producing a mycelium-based binder, comprising: providing a substrate; inoculating the substrate with mycelium;growing the mycelium; harvesting the grown mycelium in the form of a biomass as the mycelium-based binder; and curing the biomass to terminate growth.

45. The method of claim 44, wherein the substrate comprises a liquid medium and the biomass is obtained from liquid culture and collected as pellets following filtration of the culture.

46. The method of claim 44, wherein the substrate comprises a hydrogel or solid substrate and the biomass is obtained as one or more skin layers.

47. The method of claim 46, further comprising overlaying two or more of the skin layers to form a stack and allowing further mycelial growth to thicken the stack prior to curing.

48. The method of any one of claims 44 to 47, wherein the curing comprises drying at a temperature between about 45 °C and 85 °C until the humidity of the biomass is below about 10%.

49. A composite material comprising: a fibrous or granular substrate selected from one or more of a group consisting of wood fibers, cellulose fibers, agricultural fibers, wood chips, husks, and straw; and a mycelium binder fabricated by a method of any one of claims 44 to 48; wherein the mycelium binder bonds the substrate into the composite material.

50. The composite material of claim 49, wherein the composite material is in the form of a particleboard, fiberboard, a medium-density board, or a high-density board.

51. The composite material of claim 49, wherein the composite material is in the form of a chipboard, husk board, or strawboard.

52. The composite material of claim 49, wherein the composite material is in the form of a hybrid mycelium-based board further comprising one or more of a group consisting of a veneer layer, an engineered timber layer, a fiber-reinforced composite.

53. A method of using the mycelium binder of any of claims 44 to 48 as an adhesive for producing fiber-based or granular-based composite material.

54. The method of claim 53, wherein the composite material is in the form of a particleboard, fiberboard, a medium-density board, or a high-density board.

55. The method of claim 53, wherein the composite material is in the form of a chipboard, husk board, or strawboard.

56. The method of claim 53, wherein the composite material is in the form of a hybrid mycelium-based board further comprising one or more of a group consisting of a veneer layer, an engineered timber layer, a fiber-reinforced composite.

57. A method of producing a mycelium-based veneer layer, comprising the steps of: providing a substrate; inoculating the substrate with mycelium; growing the mycelium; harvesting the grown mycelium in the form of one or more skin layers as the mycelium-based veneer layer; and curing the veneer layer to terminate growth.

58. The method of claim 57, wherein the substrate comprises a hydrogel or solid substrate.

59. The method of claims 57 or 58, further comprising overlaying two or more of the skin layers to form a stack and allowing further mycelial growth to thicken the stack prior to curing.

60. The method of any one of claims 57 to 59, wherein the curing comprises drying at a temperature between about 45 °C and 85 °C until the humidity of the veneer layer is below about 10%.

61. A composite material comprising: a fibrous or granular substrate selected from one or more of a group consisting of wood fibers, cellulose fibers, agricultural fibers, wood chips, husks, and straw; and a mycelium veneer fabricated by a method of any one of claims 57 to 60; wherein the mycelium veneer covers a surface of composite material.

62. The composite material of claim 60, wherein the composite material is in the form of a particleboard, fiberboard, a medium-density board, or a high-density board.

63. The composite material of claim 60, wherein the composite material is in the form of a chipboard, husk board, or strawboard.

64. The composite material of claim 60, wherein the composite material is in the form of a hybrid mycelium-based board further comprising one or more of a group consisting of a veneer layer, an engineered timber layer, a fiber-reinforced composite.

65. A method of fabricating a mycelium-based composite product, comprising:providing a mycelium-based material comprising a mycelium-colonized substrate, the material being either (i) a crushed fibrous substrate injected into a form, or (ii) a substrate grown directly in a form; and curing the mycelium-based material by alternating hot and cold pressing steps.

66. The method of claim 65, wherein the hot pressing is performed at a temperature between about 100 °C and 200 °C under a pressure of about 1 MPa or higher.

67. The method of claim 66, wherein the hot pressing is applied for about 1-10 minutes, preferably about 1-3 minutes.

68. The method of any one of claims 65 to 67, wherein the cold pressing is performed at a temperature between about 0 °C and 30 °C under a pressure of about 1 MPa or higher.

69. The method of claim 68, wherein the cold pressing is applied for about 1-10 minutes, preferably about 1-2 minutes.

70. The method of any one of claims 65 to 69, wherein the alternating hot and cold pressing reduces the total curing time to about 2 minutes.

71. The method of any one of claims 65 to 70, wherein the alternating hot and cold pressing sequence accelerates binder development, promotes internal condensation of water vapor, and stabilizes bonding of the mycelium material.

72. A mycelium-based composite product fabricated by the method of any one of claims 65 to 71.

73. The product of claim 72, wherein the product exhibits improved bonding and mechanical properties as a result of the alternating hot and cold pressing.