Background: Filamentous fungi of the phylum Basidiomycota are considered as an attractive source for the biotechnological production of composite materials. The ability of many basidiomycetes to accept residual lignocellulosic plant biomass from agriculture and forestry such as straw, shives and sawdust as substrates and to bind and glue together these otherwise loose but reinforcing substrate particles into their mycelial network, makes them ideal candidates to produce biological composites to replace petroleum-based synthetic plastics and foams in the near future. Results: Here, we describe for the first time the application potential of the tinder fungus Fomes fomentarius for lab-scale production of mycelium composites. We used fine, medium and coarse particle fractions of hemp shives and rapeseed straw to produce a set of diverse composite materials and show that the mechanical materials properties are dependent on the nature and particle size of the substrates. Compression tests and scanning electron microscopy were used to characterize composite material properties and to model their compression behaviour by numerical simulations. Their properties were compared amongst each other and with the benchmark expanded polystyrene (EPS), a petroleum-based foam used for thermal isolation in the construction industry. Our analyses uncovered that EPS shows an elastic modulus of 2.37 ± 0.17 MPa which is 4-times higher compared to the F. fomentarius composite materials whereas the compressive strength of 0.09 ± 0.003 MPa is in the range of the fungal composite material. However, when comparing the ability to take up compressive forces at higher strain values, the fungal composites performed better than EPS. Hemp-shive based composites were able to resist a compressive force of 0.2 MPa at 50% compression, rapeseed composites 0.3 MPa but EPS only 0.15 MPa. Conclusion: The data obtained in this study suggest that F. fomentarius constitutes a promising cell factory for the future production of fungal composite materials with similar mechanical behaviour as synthetic foams such as EPS. Future work will focus on designing materials characteristics through optimizing substrate properties, cultivation conditions and by modulating growth and cell wall composition of F. fomentarius, i.e. factors that contribute on the meso- and microscale level to the composite behaviour.

Sensor-based sorting is a machine vision application that has found industrial application in various fields. An accept-or-reject task is executed by separating a material stream into two fractions. Current systems use line-scanning sensors, which is convenient as the material is perceived during transportation. However, line-scanning sensors yield a single observation of each object and no information about their movement. Due to a delay between localization and separation, assumptions regarding the location and point in time for separation need to be made based on the prior localization. Hence, it is necessary to ensure that all objects are transported at uniform velocities. This is often a complex and costly solution. In this paper, we propose a new method for reliably separating particles at non-uniform velocities. The problem is transferred from a mechanical to an algorithmic level. Our novel advanced image processing approach includes equipping the sorter with an area-scan camera in combination with a real-time multiobject tracking system, which enables predictions of the location of individual objects for separation. For the experimental validation of our approach, we present a modular sorting system, which allows comparing sorting results using a line-scan and area-scan camera. Results show that our approach performs reliable separation and hence increases sorting efficiency.

Peat is a highly contentious input in agriculture. Replacing or reducing peat by substitution with lignocellulosic biomass processed into fibre by twin-screw-extrusion could contribute to more sustainable agriculture with regard to horticultural production. Therefore, plant wastes including pruning from Olea europaea L. and Vitis spp. L., residues from perennial herbs like Salvia spp. L., Populus spp. L. and forest biomass were processed to fibre for peat replacement with a biomass extruder. The water-holding-capacity (WHC), particle-size-distribution and other physical fibre characteristics were determined and compared to peat. The specific energy demand during extrusion was measured for aperture settings from 6–40 mm. No fibre reached the 82% WHC of peat. At the setting of 20 mm of all materials investigated, Salvia performed best with a WHC of 53% and moderate specific energy demand (167 kWh t_DM⁻¹) followed by Olea europaea with a WHC of 43% and a low energy demand (93 kWh t_DM⁻¹). For Populus, opening the aperture from 20–40 mm decreased energy demand by 41% and WHC by 27%. The drying of biomass for storage and remoistening during extrusion increased the specific energy demand. Despite a lower WHC than peat, all investigated materials are suitable to replace peat in growing media regarding their physical properties.

Solid particle erosion inevitably occurs if a gas–solid or liquid–solid mixture is in contact with a surface, e.g., in pneumatic conveyors. Having a good understanding of this complex phenomenon enables one to reduce the maintenance costs in several industrial applications by designing components that have longer lifetimes. In this paper, we propose a methodology to numerically investigate erosion behavior of ductile materials. We employ smoothed particle hydrodynamics that can easily deal with large deformations and fractures as a truly meshless method. In addition, a new contact model was developed in order to robustly handle contacts around sharp corners of the solid particles. The numerical predictions of erosion are compared with experiments for stainless steel AISI 304, showing that we are able to properly predict the erosion behavior as a function of impact angle. We present a powerful tool to conveniently study the effect of important parameters, such as solid particle shapes, which are not simple to study in experiments. Using the methodology, we study the effect of a solid particle shape and conclude that, in addition to angularity, aspect ratio also plays an important role by increasing the probability of the solid particles to rotate after impact. Finally, we are able to extend a widely used erosion model by a term that considers a solid particle shape.

The numerical simulation and analysis of the ejection of an ink droplet through a nozzle as well its motion through air until its contact with a surface and taking up of a stable form is performed. The fluid flow is modeled by the incompressible Navier–Stokes equations with added surface tension. The presented model can be solved using either a level set or a phase field method to track the fluid interface. Here, the level set method is used to determinate the interface between ink and air. The presented work concentrates on the demonstration how to check the suitability of ink for inkjet printhead nozzles, for instance, for the use in printers. The results such as velocity, change of size, and volume dependence on time of an ink droplet are presented. Recommendations for the use of specific inks are also given.

Deflector wheel classifiers are widespread in industry for the separation of powders into fine and coarse powders. Even though this separation process has been known for quite some time, it is not yet fully understood, and existing models fail to precisely predict the separation characteristics. Due to the high throughput of deflector wheel classifiers, it is greatly beneficial to estimate the separation characteristics before the experiment. Here, the developed model critically examines the usual assumptions, such as ideal airflow, neglection of particle–wall and particle–particle interactions, or spherically-shaped particles. First, the investigation of the air flow using a Particle Image Velocimetry (PIV) system showed significant differences to the assumed ideal flow field, then particle sphericity and its influence on the interaction between the particles and the paddles of the deflector wheel was investigated and compared with particle rebound behavior on a static wall. Surprisingly, comminuted glass behaves similarly to comminuted limestone in multiple aspects and not like glass beads. To determine the number of particle–particle collisions, Discrete Element Method (DEM) simulations were performed. The aforementioned aspects found application in the model and the separation behavior was well-estimated.