Designing Circular Applications of Mycelium-Based Materials for Aircraft Cabins

Abstract

This graduation project (Hyfen) elucidates opportunities for mycelium-based innovations in circular aircraft cabin design with a focus on material properties, applications and comparative environmental impacts.
Aircraft cabin interior elements account for 10% of an aircraft’s empty weight, and are replaced 4-5 times during the lifetime of an airframe. Thus, cabin elements are responsible for a significant portion of an airliner’s environmental impacts due to operational emissions and improper waste handling. An understanding of the need to apply circular principles to the cabin led to
heightened interest in mycelium-based materials which are lightweight and biodegradable.

The design goals were 1) Understanding the material properties of mycelium-based materials based on aircraft cabin requirements 2) Identifying optimal applications of mycelium-based materials in an aircraft cabin and developing selected demonstrators & detailed designs 3) Assessing the circularity and comparative Life Cycle Impacts of selected applications.

These goals were achieved through an adaptation of the Material Driven Design methodology. The outcomes of this project included conceptual design and demonstrators of two applications. First, is an optimized bionic partition with mycelium acoustic panels and filler material, weighing 40% less (41,6 kg) than a conventional nomex honeycomb-based composite partition (67 kg). The second is a modular packaging cum meal tray for airlines, aiming to reduce single-use plastic waste.
These specific applications were detailed to highlight the temporal & versatile properties such as competitive insulation (acoustic & impact), damage-resistant textures, foam-like compressive properties, mouldability into complex shapes and comfortable tactile interactions for passengers. They also have a high potential to mitigate the environmental impacts of an aircraft cabin due to weight savings in the bulky interior panels, as demonstrated by a final circularity and fast-track life cycle assessment.
Takeaways from this thesis also include insights into the optimal application families, including hot & cool cases, galley, business class & first class seat shelving systems, cushions and upholstery for seats and even decorative filler material for armrests and accessories. These applications to different degrees, leverage the unique material properties (e.g. low weight, mouldability, apparent sustainable advantage, warm & comforting textures etc.) of pure mycelium and
myco-composite materials. It also adds to an understanding of the design requirements for circular applications using mycelium derivatives and aims to inspire further research & development for deployment.

This thesis provided conclusive foundational qualitative evidence on the potential environmental advantage of mycelium applications over plastics, composites and other petroleum-derived materials in an aircraft cabin. Future recommendations include looking into standardization, commercialization, usability and acceptance. Project Hyfen aimed to be visionary and embolden the stringent aerospace sector to seek solutions in nature for its circularity transition - with biobased materials like mycelium being the building blocks, literally and figuratively