Design’n’Grow Studio - explorations in upscaled biofabrication

Scaling up mycelium Engineered Living Materials (ELMs) presents opportunities and challenges for architectural design, particularly in understanding scale-related and unrelated properties of constructing with living materials. While Mycelium-Based Composites (MBCs) offer promising physical properties and environmental benefits , their scalability remains underexplored. Previous studies (Le Ferrand, 2024; Elsacker, 2022; Ross, 2016) identified oxygen and carbon dioxide penetration as limiting factors, constraining mycelium growth beyond a depth of 15 cm. Bio-welding techniques have enabled the creation of larger blocks (400 × 550 × 400 mm) (Elsacker, 2022), addressing some of these challenges. This research employs a hands-on experimental approach, constructing large-scale (200 × 80 cm) demonstrators to investigate bio-welding and air penetration constraints. Moving beyond volumetric mass, the study explores speculative fabrication strategies for facade panels, allowing for geometric customization within the biofabrication process. Three methods were tested: (1) sacrificial molding with textile sheets, (2) bio-welding of textile-mycelium filaments, and (3) bio-welding of mycelium blocks. Using a consistent mycelium mixture (80 wt% sawdust, 20 wt% straw, and Ganoderma lucidum), additional additives (2 wt% guar gum, 1 wt% psyllium husk) facilitated extrusion-based filament production. Results showed successful large-scale mycelium growth with minimal contamination. Method (1) yielded strong bio-welding but posed drying challenges. Method (2) faced alignment and humidity control issues, while method (3) demonstrated partial success but structural weaknesses. The study highlights grassroots experimentation’s potential in scaling up MBCs while underscoring the need for further research into process refinement and scientific rigor.