Biowelding 3D-Printed Biodigital Brick of Seashell-Based Biocomposite by Pleurotus ostreatus Mycelium

Mycelium biocomposites are eco-friendly, cheap, easy to produce, and have competitive mechanical properties. However, their integration in the built environment as durable and long-lasting materials is not solved yet. Similarly, biocomposites from recycled food waste such as seashells have been gaining increasing interest recently, thanks to their sustainable impact and richness in calcium carbonate and chitin. The current study tests the mycelium binding effect to bioweld a seashell biocomposite 3D-printed brick. The novelty of this study is the combination of mycelium and a non-agro–based substrate, which is seashells. As well as testing the binding capacity of mycelium in welding the lattice curvilinear form of the V3 linear Brick model (V3-LBM). Thus, the V3-LBM is 3D printed in three separate profiles, each composed of five layers of 1 mm/layer thickness, using seashell biocomposite by paste extrusion and testing it for biowelding with Pleurotus ostreatus mycelium to offer a sustainable, ecofriendly, biomineralized brick. The biowelding process investigated the penetration and binding capacity of the mycelium between every two 3D-printed profiles. A cellulose-based culture medium was used to catalyse the mycelium growth. The mycelium biowelding capacity was investigated by SEM microscopy and EDX chemical analysis of three samples from the side corner (S), middle (M), and lateral (L) zones of the biowelded brick. The results revealed that the best biowelding effect was recorded at the corner and lateral zones of the brick. The SEM images exhibited the penetration and the bridging effect achieved by the dense mycelium. The EDX revealed the high concentrations of carbon, oxygen, and calcium at all the analyzed points on the SEM images from all three samples. An inverted relationship between carbon and oxygen as well as sodium and potassium concentrations were also detected, implying the active metabolic interaction between the fungal hyphae and the seashell-based biocomposite. Finally, the results of the SEM-EDX analysis were applied to design favorable tessellation and staking methods for the V3-LBM from the seashell–mycelium composite to deliver enhanced biowelding effect along the Z axis and the XY axis with <1 mm tessellation and staking tolerance.