Large-scale production of fungal melanin for novel radiation shielding/harvesting applications

The optical and physicochemical properties of melanin polymers are unique and can be applied to generate a new class of products with a wide variety of commercial applications that include radiation shielding countermeasures, camouflage/screening, thermal energy harvesting, and insulation.  Access to melanin is currently limited to Sepia officinalis (cuttlefish) at $460/g which prohibits its use for military applications due to its high cost. Therefore, the Research Development (R&D) and commercialization of melanin-based technologies require the development of a scalable and cost-effective production process to provide a plentiful supply of melanin at a reasonable cost. Fungal sources of melanin present an unparalleled and untapped opportunity to produce high-quality melanin at large scales and at a production cost that can enable the R&D of technologies for multiple applications and market sectors. During the Phase I effort, MelaTech demonstrated the technical feasibility of a laboratory bench scale process to produce fungal melanin and met stated goals about optimization and production. We optimized the growth conditions for faster melanization and higher melanin yields, exceeding our productivity goal from approximately 1 g to 4 g of melanin per week. We presented a melanin composite solid prototype material and began characterizing its relative ability to shield and absorb different radiation frequencies; from X-rays to microwaves. The melanin composite is compatible with additive manufacturing and was used to 3D-print a cylindrical chamber to study microwave shielding. Finally, we demonstrated the structural stability of pure melanin after storage at different temperatures and humidity. Hence, in Phase I, we met all our goals, exceeded planned milestones, and developed the technology for Phase II.   The objectives for Phase II are to establish a pilot-scale process for fungal melanin production and continue to characterize the relative ability of pure melanin and the melanin solid prototype material to shield and/or absorb different radiation energies. The scale-up effort will be done by MelaTech with the support of experts in the yeast biomanufacturing industry. The characterization effort will be done in collaboration with melanin experts at The Johns Hopkins Bloomberg School of Public Health (JHU). Upon completion of Phase II, we anticipate (1) establishing a practical scale-up approach to producing fungal melanin at pilot scales that will guide further developments at industrial scales, (2) increasing melanin production by approximately 10 times, and (3) demonstrating the relative capacity of melanin and a melanin solid prototype material to shield and absorb X-ray, ultraviolet, visible, infrared, and microwave frequencies. Accomplishing this will increase the supply and demand of melanin and guide the R&D of products for multiple commercial applications that are relevant to the government and private sectors.