Research from Swinburne University of Technology suggests old mattresses could be repurposed into building insulation through a manufacturing process that uses fungi to bind shredded foam into a solid, lightweight material.
The findings, published in Nature’s Scientific Reports journal, detail how Swinburne researchers combined a common fungus with waste mattress foam to create an insulation material with performance comparable to existing commercial products, while addressing one of the most challenging waste streams in household recycling.
Swinburne researchers Dr The Hong Phong (Peter) Nguyen, Associate Professor Mostafa Nikzad and Dr Huseyin Sumer said mattresses are difficult to recycle due to their size, durability and mixed materials.
“Mattresses are durable, bulky, and often end up in landfill,” said Dr Nguyen, an engineering expert at Swinburne. “Through natural biological processes, we can give this waste a second life.”
According to the researchers, the process relies on fungal root structures binding to the shredded foam, forming natural mineral compounds. These compounds were found to resist extreme heat and remain stable at temperatures close to 1,000 degrees Celsius.
“The material performed well as an insulator, with heat-blocking ability very close to commercial insulation products already used in homes and buildings,” Dr Nguyen said.
He added that the approach was designed with practicality in mind. “The approach is both practical and environmentally responsible, using fungus that is closely related to strains used in food production and medicine, and relying on common, widely used chemicals,” he said.
The scale of mattress waste in Australia was highlighted by Australian Bedding Stewardship Council Director of Innovation Tracey Pryor, whose organisation co-funded the research. Pryor said about 1.8 million mattresses are disposed of each year.
“740,000 mattresses are still sent to landfill, equating to approximately 22,000 tonnes of needless waste that can take up to 120 years each to decompose,” she said.
Dr Nguyen said further research and development would be needed before broader adoption, but noted the material’s potential for future manufacturing applications.
These could include fire-resistant insulation, building panels or components shaped for emerging construction techniques such as 3D printing.
“Our work shows how combining biology with waste materials, while leveraging deep manufacturing science, can lead to smart, low-impact solutions that better the environment and the lives of everyone,” Dr Nguyen said.
