Structure–Property Relationships and Prototype-Scale Performance of Geothermal Microbial Mat-Derived Organo-Mineral Composites

Thermal microbial mats are laminated organo-mineral biofilms composed of extracellular polymeric substances (EPSs) and microbially mediated silica and carbonate phases. Although extensively studied from ecological and geobiological perspectives, their potential as precursors for applied, bio-derived composite materials remains largely unexplored. In this study, geothermal microbial mats from the Comanjilla hot springs (Mexico) are investigated from a materials-oriented perspective through controlled processing, inorganic tanning, and polymeric surface conditioning. The mats were treated with potassium alum and reinforced using a polyvinyl alcohol–alginate–glycerin formulation to improve cohesion, handling behavior, and structural stability. Mineralogical, physicochemical, and microstructural analyses reveal a hierarchical laminated architecture in which EPS functions as a continuous organic matrix, while in situ silica and carbonate phases provide intrinsic mineral reinforcement. Carbonate-rich mats yield softer and more flexible composite materials, exhibiting tensile strength values of 2.17 ± 0.18 MPa and elongation at break of 15–20%, whereas silica-rich mats produce stiffer and more abrasion-resistant systems. Thermal analysis shows a main organic decomposition event near 275 °C and a stable inorganic residue of approximately 45–50 wt%, confirming the hybrid organo-mineral nature of the processed materials. Prototype-scale fabrication demonstrates structural cohesion, controlled porosity, elastic recovery, and breathability, supporting potential low-load and non-structural applications. Overall, the results identify geothermal microbial mats as a renewable and naturally pre-assembled platform for bio-derived organo-mineral composite materials and provide a foundation for future studies focused on controlled processing and structure–property optimization.