The demand for sustainable alternatives to traditional materials like leather has driven research into biomaterials that mimic leathers functional and aesthetic properties. Our research explores the development of a leather-like composite utilizing a Fusarium sp., a fungus known for its biological versatility, robust growth, and safety. Using this fungus as an alternative to leather and other composite materials has potential economic and ecologic advantages as the process uses sustainable resources, minimizes waste generation, can recycle waste textile streams, and is highly scalable. The process involves culturing Fusarium sp. in a low cost nutrient medium to promote growth of fungal mycelium as sheets, which serve as the primary structural component. To enhance the mechanical properties and potential applications of the material, fabric can be integrated with the fungus to create a composite material. The mycelium grows into the fabric matrix, creating an integrated hybrid material that combines the strength and flexibility of the fungal network with the tensile properties of the textile component.

Growth conditions can be manipulated to produce mats of varying thickness, from 1 millimeter up to 3 cm. The mycelium composite can be thermally processed to improve material density, surface smoothness, and overall durability. The thermal processing is optimized to achieve a balance between structural integrity and aesthetic qualities, such as texture and color. The synthetic leather samples can be augmented with biochemicals to enhance flexibility and moisture retention.

Preliminary results demonstrate that the fungal-based composite exhibits mechanical properties that could be comparable to conventional leather, including flexibility, thickness, and resistance to tearing. Ongoing work involves further quantifying properties such as tensile strength, UV resistance, and abrasive toughness. Utilization of Fusarium sp. in leather-like composites contributes to sustainable economies and the continued development of novel engineered living materials.