<p>Driven by the urgent need to identify sustainable alternatives to petroleum-based plastic packaging, this study evaluates the environmental performance of mycelium bio-foam (MBF) as a substitute for expanded polystyrene (EPS) in protecting a 32-inch flat-screen television (32-TV). A cradle-to-grave life cycle assessment (LCA) was conducted using OpenLCA software and the ELCD database to compare the impacts of MBF and EPS. The results indicate that MBF packaging offers lower environmental impacts overall, particularly during raw material acquisition, manufacturing, and end-of-life management stages. Global warming potential (GWP) (kg CO₂ eq) for MBF50, MBF100, and MBF150 was 1.32, 2.16, and 3.24, respectively, significantly lower than EPS at 3.35 kg CO₂ eq. Similarly, human non-carcinogenic toxicity (kg 1,4-DCB) values were 4.3, 6.2, and 9.3 for MBF variants, compared to 9.3 for EPS. In the transportation phase, MBF incurred higher global warming impacts (0.9 × 10^–3 to 2.8 × 10^–3 kg CO₂ eq) than EPS (0.4 × 10^–3 kg CO₂ eq) due to its higher weight. However, these emissions are offset by MBF’s biodegradability and potential for circularity. The findings underscore the importance of optimizing MBF packaging weight and design to enhance both environmental and economic viability. MBF emerges as a promising sustainable alternative to EPS, though continued innovation in material engineering and packaging design remains essential. Promoting the environmental benefits and cost-effectiveness of MBF packaging is key to accelerating its market adoption.</p> Graphical abstract <p></p>