Spark Thermionics, Inc.

Spark Thermionics, Inc., a small-business manufacturer of advanced thermionic energy conversion systems and high-temperature materials, operates as a prime contractor (91% of recent awards) across federal defense, space, and energy research programs, with all prime work awarded under total small business set-asides. The Berkeley, California-based company specializes in thermionic power generation for extreme-environment applications, including hypersonic vehicles, space systems, soldier equipment, and microreactor operations, and maintains a 11,000 square-foot facility with specialized testing infrastructure capable of operating thermionic devices at temperatures ranging from 1,000 to 1,500 degrees Celsius.

Spark Thermionics holds a concentrated customer footprint anchored by defense and space research agencies. Defense Advanced Research Projects Agency leads by potential value at $9.3 million across five awards (53% of combined potential value), while the Department of the Army Research, Development and Engineering Command, Department of the Air Force Research Laboratory, Defense Logistics Agency Troop Support, and Army PEO Soldier account for the remainder of the 88% coverage. The Air Force Research Laboratory carries six awards totaling $1.6 million; the Army RDECOM and DLA Troop Support each carry two awards for $1.9 million and $1.3 million respectively. This concentration reflects Spark's embedded position in applied and basic research programs rather than production or sustainment work.

Recent activity has accelerated materially. Awards per year climbed from one in both 2023 and 2024 to six in 2025, with the most recent award a $1.2 million Defense Logistics Agency definitive contract on March 30, 2026, for affordable integrated surface modification of ceramic and refractory substructures with ultra-high-temperature ceramics for thermal protection system materials. Only two awards (combined potential value $1.3 million) face ultimate completion within the next twenty-four months, limiting immediate recompete exposure. Spark holds a $6.7 million DARPA Other Transaction IDV for large-area photocathode technology development awarded June 18, 2025, which operates outside the FAR and serves as a multi-year vehicle for photocathode design, fabrication, testing, and optimization work.

Spark's contract portfolio emphasizes Small Business Innovation Research Phase II awards, which dominate the prime footprint — a $1.25 million Air Force Research Laboratory Phase II contract (February 2024) for power generation systems for hypersonic vehicles, a $1.7 million Army RDECOM Phase II (December 2021) for liquid-fuel thermionic battlefield generators, and a $750 thousand NASA Phase II (April 2022) for thermionic energy conversion systems for hypersonic applications represent the scale of historical engagement. The company also received a $100 thousand Small Business Technology Transfer Phase I from Defense Logistics Agency Troop Support (July 2025) and a $250 thousand Army SBIR Phase I (March 2025) for hybrid electric powertrain and propulsion systems. Grant work includes a $200 thousand Department of Energy Office of Science award (July 2025) for thermionic energy conversion for unattended microreactor operations, and a sub-award role under a University of Michigan grant to provide thermionic energy conversion expertise. In subcontract capacity, Spark serves as a subsystem developer to a prime contractor on the DARPA large-area photocathodes program. The combined $14.8 million in obligated dollars reflects active execution across 23 total awards spanning research, development, and early prototype phases rather than production volume.