NXT MFG wins $10K award from TVA to advance 3D metal printing technologies
The Tennessee Advanced Energy Business Council hosted a Demo Day for the Spark Cleantech Accelerator at the annual Opportunities in Energy event.
For the past three months, 12 cleantech companies from across the country have been incubating and accelerating their innovations from an East Tennessee base. The goal of the program is to begin the process of commercializing their advanced technologies for real-world applications.
This semester, about six of the participants came to Knoxville exclusively for the Spark Program at UT Research Park, and six enrolled in the accelerator due to their admittance to the Innovation Crossroads program at Oak Ridge National Laboratory (ORNL). Much of the cohort features new faces, but a couple are familiar to the East Tennessee entrepreneurial community. Brian Washington, the founder of AluminAiry, and Lance Adler, the Founder of Witching Hour, have both previously participated in Spark, but this time are participating on behalf of Innovation Crossroads.
2025 Spark Demo Day
NXT MFG caught the eye of TVA during the 2025 Spark Cleantech Accelerator Demo Day. Brad Chadwell, the Director of Enterprise Research & Innovation at TVA, announced that Dr. Eric Heikkenen, the co-founder and CEO of NXT MFG, won a $10,000 award from the utility giant.
Heikkenen obtained his PhD in Mechanical Engineering from the Tickle College of Engineering at the University of Tennessee, Knoxville. His company, NXT MFG, emerged from stealth about six months ago, right before joining the Spark Accelerator.
NXT MFG has invented an adaptive process control approach for 3D metal printing, which has the potential to make industrial-grade additive manufacturing practical and accessible for electric utilities and other industries.
“I live it, I breathe it, sometimes it gets a little weird when I dream about it,” Heikkenen laughed during his pitch, emphasizing his passion for what he’s bringing to market.
Pitches: Advanced Materials
Alec Readel presented his startup, Applied 2D Materials, which is an Innovation Crossroads company. His unique 2D coating uses hexagonal boron nitride on common metals to make high-performing materials.
Ian Ramsdell presented his startup, Kupros, which has secured about $400,000 in funding to commercialize his all‑metal conductive filament called “Cu‑29,” which is designed for use in standard FDM/FFF 3D printers. Ramsdell talked about how Cu-29 could help Kupros 3D print fully functional circuits, sensors, antennas, and EMI shielding.
Evan Stacy presented his company, Lumios Materials, which is scaling a proprietary photoiniferter polymerization process—in water—for producing ultra-high molecular weight, low-dispersity polyacrylonitrile (PAN) carbon-fiber precursors.
“We’re here to make carbon fiber production cheaper, faster, and stronger,” Stacy said.
Pitches: Energy Efficiency
Brian Washington, founder of AluminAiry, was the 2024 Demo Day recipient of the $10,000 award from the TVA. He is participating in the Spark Cleantech Accelerator for the second time on behalf of the Innoavtion Crossroads program.
Washington is developing recyclable aluminum-air battery systems for stationary residential and commercial power applications.
Sasimon Viriyayuthakorn, a team member for the startup Ecosnap, presented their innovative HVAC connection technology. Their innovative ductless mini‑split heat pump system enables fast, tool‑free installation with no refrigerant handling or an electrician required.
Viktor Zenkov, the founder of Efusio, presented his startup, which is focused on a new way to cool electronic and data centers. His patent-pending thermodynamic refrigeration system called “IoniCool” combines vapor-compression and absorption refrigeration cycles into a novel hybrid design that dramatically reduces energy consumption for cooling electronics.
Pitches: Housing & Construction
Ginger Watkins, the founder of ORB Technologies, presented her company, which aims to catalyze the transformation of the building industry from a carbon source to a carbon sink by developing a novel plant-based, load-bearing, and fire-resistant insulation.
Maged Guerguis, the founder of OTTO Prefab, presented his designs for modular, prefabricated building systems that combine advanced materials and automation to streamline construction and reduce waste. His company specializes in designing cost-effective, sustainable structures for residential and commercial applications, featuring rapid assembly and minimal environmental impact.
Helen Banner, the founder of ALGENOVAS, which uses algae-based biocomposites to repurpose algae biomass and agricultural waste into durable materials for packaging and construction.
Pitches: Robotics
In addition to Eric Heikkenen, founder of NXT MFG, and winner of the $10,000 TVA award, two others pitched in the robotics category.
Joining Spark from Ohio, Kendall Byrd pitched Caddis Tech. His company builds autonomous aquatic drones equipped with UV‑C LED systems that eliminate algae in small waterways without using toxic chemicals. These battery-powered “Roomba‑for‑water” drones treat around 15 gallons per minute, offering a scalable, eco‑friendly approach to maintaining clean ponds, small lakes, and reservoirs.
Lance Adler also took the stage to pitch his Witching Hour startup. His company is developing drone technology for utility and powerline maintenance, applying coatings to reduce the risks of wildfires.
In September, Adler won the top prize at the 865 Fest Startup Pitch competition, securing $10,000 in non-dilutive funding.
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