As the need to move towards a circular economy increases and dependence on fossil fuels decreases, the need for new sustainable materials is growing. Fungal biocomposites are a natural alternative to synthetic foams. In addition to understanding the material properties, it is important to know how to produce large quantities of these materials with the appropriate properties in order to successfully commercialise the technology and develop products. As part of our experimental work, we have produced a large low-density fungal biocomposite with a volume of 47 litres and a length of two metres. The final fungal biocomposite was produced by growing mycelium in three stages, first in culture bags, then in two larger moulds which were fused together in a third stage. We used a culture of Ganoderma resinaceum and a specially formulated low-density substrate made of straw, coconut fibre, brewers' spent grain, coffee grounds and wheat flour. The results showed that the final biocomposite, with a density of 80 kg/m³, met the size targets, remained free of infestation and tolerated lighter loads. The main drawback of the material was the minor indentations on the surface of the material which happened due to air pockets in the substrate at the transfer of mycelium into the mould.
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