Parameter Development for the Scaled Manufacturing of Mycelium Bound Panels for Commercial Interior Products

EPA Contract Number: 68HERD19C0005
Title: Parameter Development for the Scaled Manufacturing of Mycelium Bound Panels for Commercial Interior Products
Investigators: Tudryn, Gregory J
Small Business: Ecovative Design, LLC
EPA Contact: Richards, April
Phase: II
Project Period: December 1, 2018 through November 30, 2020
Project Amount: $299,148
RFA: Small Business Innovation Research (SBIR) - Phase II (2018) Recipients Lists
Research Category: Small Business Innovation Research (SBIR) , SBIR - Green Buildings Materials and Systems

Description:

 

Project Summary

 

Ecovative Design uses grown mycelium structures to bind agricultural and wood byproducts into inherently non- toxic products containing no added urea formaldehyde or flame-retardant chemicals. This research program focuses on maturing mycelium technology for use in the production of large scale board products, from low density (LD) particle board to acoustic panels and thermal insulation. The Phase I work resulted in the successful build out and demonstration of a new manufacturing process called the Bulk Bin Reactor (BBR) and production of panel sizes previously unachievable. Additionally, it was discovered that grinding and hot pressing are not required, and as- grown material can outperform the internal bond of LD particle board.

 

Phase II work will introduce new substrates to the BBR system to improve material properties. Targets are enhanced insulation, acoustic attenuation, and flame resistance. Objective I will produce hemp-based panels – known from small scale work to be high performing in the target attributes. Objective II will screen lower density, higher performance substrates. A commercialization plan is also laid out to take the results of the Phase II research and begin field testing the resulting panel products, and to prepare technical and financial information to begin partnerships with potential licensee manufacturers in industry sectors.


SBIR Phase I:

Growth and Fungal Resin Generation for Manufacturing Novel, Formaldehyde-Free Wood Particleboard  | Final Report