SBIR Phase II: Using Mycelium as a Matrix For Binding Natural Fibers And Core Filler Materials in Sustainable Composites

这个小型企业创新研究(SBIR)第二阶段项目寻求进一步量化真菌生物复合材料的机械性能，以满足汽车和结构核心行业的需求，同时扩大和展示材料生产。工程复合材料市场继续稳步增长，因为与传统工程材料相比，这些系统具有较高的强度/重量比和刚度/重量比。工程木材在建筑和家具行业无处不在，但由于国内室内空气质量法规(有毒物质控制法)，这些材料正被逐步淘汰，或被迫使用昂贵的无甲醛粘合剂。同样，欧洲的汽车行业也面临着监管压力，要求它们寻找因无机填充剂而无法回收的阻燃泡沫的替代品。第一阶段工作的技术成果表明，生物复合材料在经济上和机械性能上都可以与上述竞争对手竞争，同时满足这些立法要求。根据我们现有生产设施项目的工艺经济性进行的初步成本分析显示，汽车和家具行业的零售成本分别比目前最先进的水平低45%和35%。我们将与主要行业合作伙伴合作，满足性能指标并展示高质量的试生产。该项目的更广泛影响/商业潜力将是一种可定制的生物复合材料，适用于广泛的市场，包括汽车、交通、建筑、家具、体育和娱乐。这些材料是真正可持续的，因为夹层结构中使用的层压板和芯材都是可再生材料。与其他生物兼容复合材料相比，它们需要的能量也要少得多，因为材料是生长的，而不是合成的，而且材料在使用寿命结束时完全可以堆肥。建议的开发和示范结果将确保生物复合材料性能满足目标市场的要求。此外，在这笔赠款的过程中，并与伦斯勒和联合学院合作，我们将演示最佳制造工艺并将其扩展到能够制造大量高质量产品的试点阶段。由于这些材料利用来自国内农业和工业的地区性木质纤维副产品，目前正在寻求一种地区性制造模式，以降低运输和原料成本。这不仅将为美国农产品市场带来额外价值，还将通过国内制造业刺激农村经济发展。最后，这些先进的生物材料代表了制造业的新范式，提供了传统石油替代品的安全、可生物降解的替代品。

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