Our Pilot Plant
Ecovative’s Pilot Plant facility in Green Island, NY is where we use the magic of mycelium to bring grown products to life.
We have two main methods of growing mycelium products.
Molded Shapes and mCore Panels and Blocks
Our molded shapes platform is best for applications like packaging, home accessories, and other smaller molded shapes where complex geometry is important.
At Ecovative, we use recyclable thermoformed trays to grow our molded shapes. These trays are reusable and we refill them every week.
We call these “growth trays.” We fill them with a myceliated agricultural byproduct. Over a period of six days, the mushroom mycelium grows throughout the substrate. Mycelium is metaphorically the root structure of the mushroom. After six days we take the grown parts out of the growth trays and put them in our industrial kiln to dry and kill the mycelium. There are no spores or mushrooms at this point, just the mushroom roots.
Ecovative covers the costs and responsibilities for making and maintaining a stock of the growth trays. We make parts every week for longer periods of time to maximize our sustainability and provide lower costs to the customer.
Standard Shapes in our Shop
We keep our most popular molded shapes in stock and ready for purchase! Check out our Shop for a look at our available products.
Custom Molded Shapes
Not seeing what you need in our Shop? Good news! Anything you can imagine that is thermoformable, we can grow into a custom shape. Use our quoting tool to get the process started.
Min. Size of Shape
2 in. x 2 in. x 2 in.(5 cm x 5 cm x 5 cm)
Max. Size of Shape
18 in. x 18 in. x 5 in.(46 cm x 46 cm x 13 cm)
- Home Accessories
- Small, Complex Shapes
Step 1: We create CAD drawings for your shape
Step 2: We create custom tooling for your shape
Step 3: We grow a prototype for you to approve
Dell Molded Shape Case Study
We designed packaging components to replace fabricated EPE-polyethylene foam parts that provide cushioning and bracing in large packages for Dell servers. These packages tip the scales at over 200lbs (90kg), and these sensitive servers require the utmost protection. Ecovative’s packaging design team worked with Dell's packaging engineers to create a shape that would protect the hard drives from experiencing damaging G loads in the event of a drop.
mCore Panels and Blocks
Ecovative has developed a manufacturing system to grow large blocks of mycelium / wood composites. These can be cut, sanded, and used as ultra low density particle board panels or shaped into large volumes. Perfect for a wide range of applications from theater sets to wetland rafts to acoustic barriers.
Ecovative’s mCore Panels and Blocks are produced using our patented biomaterials platform which uses mycelium, a self assembling biological binder, to grow a lightweight gap filling glue. 100% BioBased mCore Panels and Blocks meet the highest standards for sustainable goods, including C2C Gold Certification, yet perform well in demanding applications. Standard Properties can be downloaded here, though can be modulated for custom orders.
Unlike our molded shapes, Ecovative's mCore Panels and Blocks are produced using our Aerated Bed Reactor process. Panels are cut from large blocks which are grown over the course of 9 days in modified industrial composting infrastructure. The growth process is robust enough to operate in open lanes within an inexpensive standard warehouse, unlike many existing bio-materials processes which require highly sterile growth environments. While our research scale production cost out of our Green Island facility ranges from $30-60 per cubic foot, these materials can be produced for under $2 per cubic foot when implemented at scale.
Max. Size of Block
36 in. x 40 in. x 24 in.(91 cm x 102 cm x 61 cm)
- Large flat panels
- Single season floating rafts for wetland restoration and aquaculture
- Temporary displays, signage, and theater sets
- Acoustic panels and barriers
- Door cores
mCore Panel being sanded to be used as a floating wetland raft
Whole mCore Block being lifted with forklift