Spark Industries MFG LLC

Spark Industries MFG LLC, doing business as Trident Energy Systems, is a Virginia-based manufacturer specializing in advanced additive manufacturing capabilities, particularly wire arc additive manufacturing (WAAM) technology. As a minority-owned, veteran-owned, service-disabled veteran-owned, and Native American-owned small business, Spark Industries has established itself as a qualified federal contractor capable of producing precision metal components for defense-related applications. The company leverages cutting-edge additive manufacturing techniques to deliver complex metal parts with enhanced material efficiency and reduced production timelines compared to traditional subtractive manufacturing methods.

Spark Industries MFG LLC has demonstrated its technical expertise through multiple federal prime contract awards spanning different agencies and project scopes. The company received a Firm Fixed Price BPA Call contract from the U.S. Army Engineer Research and Development Center on September 16, 2025, valued at $163,900, for the fabrication of a sector gear top hinge utilizing wire arc additive manufacturing in accordance with detailed specifications. This Total Small Business set-aside contract required performance in Gainesville, Virginia, with completion targeted for November 26, 2025. Additionally, the company was awarded a $74,874 firm-fixed-price purchase order from the U.S. Air Force Research Laboratory on May 13, 2024, as a Small Business Innovation Research (SBIR) Phase I contract. This AFRL award, also designated as a Total Small Business set-aside, focused on zero-carbon fuel cell electric light and heavy-duty ground transportation research, with an ultimate completion date of August 19, 2024. These contract awards reflect Spark Industries' capabilities in both manufacturing precision components and participating in advanced technology research and development initiatives.

Spark Industries MFG LLC holds a Master Blanket Purchase Agreement with the U.S. Army Corps of Engineers' Engineer Research and Development Center, awarded on August 5, 2025, with a $750,000 ceiling value and an active period extending through November 15, 2028. This multiple award BPA, which operates without set-aside provisions, establishes a framework for the ERDC to issue task orders for Wire Arc Additive Manufactured (WAAM) parts as needed throughout the contract period. Under this indefinite delivery vehicle structure, Spark Industries serves as a prime contractor responsible for manufacturing and delivering additively manufactured components according to specifications outlined in individual task orders. The BPA mechanism provides the ERDC with flexible access to the company's advanced additive manufacturing capabilities to support research, development, and operational needs while maintaining cost control through the established ceiling. This contract vehicle enables the government to evaluate and integrate wire arc additive manufacturing technology into defense and military engineering projects while leveraging Spark Industries' expertise in rapid prototyping, material efficiency, and cost-effective production of complex metal parts.