Innovator Story: Sperra
Innovation Beneath the Sea: How NYSERDA Propelled Sperra’s 3D Energy Storage Revolution
Armed with a unique blend of 3D concrete printing, energy storage innovation, and a fierce dedication to sustainability, Sperra is taking on one of the greatest challenges of our time: how to store clean energy at scale. And thanks to critical early support from NYSERDA, that vision is taking concrete form—literally.
A Bold Beginning: From National Labs to Concrete Dreams
Sperra took shape through the ingenuity and persistence of founder Jason Cotrell, who spent over two decades at the National Renewable Energy Laboratory (NREL). While there, he became intrigued by the emerging field of 3D concrete printing, particularly its potential applications in renewable infrastructure. Cotrell took a leap of faith, leaving NREL to form what would become Sperra.
Early on, the team was small, held together by a shared vision and early grant funding. Gabriel “Gabe” Falzone, now COO, joined Sperra in 2020 with a background in material science and low-carbon cement development. Evan Marquardt, an Energy Storage Sr. Project Manager, brought an engineering career rooted in high-speed innovation. Together, they helped Sperra transition from concept to capability.
From Printing Towers to Storing Power: How Sperra’s Technology Works
Sperra’s technological breakthrough lies at the intersection of 3D concrete printing and subsea energy storage. Using enormous, gantry-style 3D printers—including what was once the world’s tallest, now housed in a repurposed GE facility near Rochester—the company can produce immense, spherical concrete structures up to 100 feet in diameter.
These spheres are not architectural novelties; Sperra builds on technologies developed by MIT and the Fraunhofer Institute to create infrastructure that tackles clean energy storage and climate resilience. Here’s how it works:
- Energy Surplus: When renewable energy sources produce more than the grid needs, a pump inside the submerged sphere expels water, creating a vacuum.
- Energy Demand: When electricity is needed, seawater flows back, turning the reversible pump into a turbine to generate power.
This approach delivers long-duration, efficient storage—without the land use or resource constraints of batteries or traditional pumped hydro. And because these systems are offshore, they can piggyback on existing energy infrastructure, reducing costs and streamlining deployment.
This underwater solution solves a major barrier to renewable energy: long-duration energy storage. Traditional pumped-hydro systems are constrained by geography and water availability. Sperra’s ocean-based system, by contrast, leverages existing offshore wind infrastructure, avoids land-use conflicts, and remains completely invisible to the public—deep, clean, and quiet.
“It’s a huge signal,” said Marquardt. “Being vetted by a public [authority] like NYSERDA, with its reputation and mission focus, makes a big difference when we go to equity investors or partners. It tells them we’re serious.”
— Evan Marquardt, Energy Storage Sr. Project Manager
The NYSERDA Effect: From Seed Funding to Strategic Partnership
None of this would have been possible without NYSERDA’s early and ongoing support. Sperra’s first NYSERDA grant, awarded in 2021, allowed the team to explore how 3D printing could be applied to these massive storage spheres—an inherently complex challenge.
According to Falzone, funding was “a huge stepping stone” in pushing from feasibility to physical prototype. It allowed Sperra to build and assemble a 2-meter proof-of-concept sphere and begin developing full-scale manufacturing systems. The grant didn’t just fund research—it brought credibility.
“It’s a huge signal,” said Marquardt. “Being vetted by a public [authority] like NYSERDA, with its reputation and mission focus, makes a big difference when we go to equity investors or partners. It tells them we’re serious.”
Sperra’s relationship with NYSERDA has included more than just dollars. Mentorship, industry introductions, investor networking, and even support in refining go-to-market strategies have all played a part. Project managers at NYSERDA also maintain active engagement with the Sperra team, ensuring alignment with state priorities and offering valuable feedback and accountability.
Transformative Benefits for New York and Beyond
The Rochester facility is more than a manufacturing hub—it’s a launchpad. After acquiring the GE research site, Sperra quickly set up operations, supported by NYSERDA and regional partners like the Genesee County Economic Development Council.
The decision for Sperra to expand into New York was part opportunistic, part strategic. The region offers skilled engineering talent, proximity to ports, and the potential for deep community engagement. Sperra had already begun outreach with local universities, elected officials, and workforce development organizations, hoping to build a pipeline of local apprentices, interns, and full-time hires.
Sperra’s subsea storage solution offers a promising new model for clean energy infrastructure, with tangible benefits for both people and the planet:
Long-Duration Energy Storage
Delivers consistent, dispatchable power that supports the full integration of renewables.
Sustainable Materials
Uses low-carbon concrete, reducing the carbon footprint of storage systems.
Coastal Resilience
Supports climate adaptation by doubling as resilient offshore infrastructure.
Low Environmental Impact
Minimizes reliance on mined materials and avoids pollution.
Advanced Manufacturing Jobs
Creates high-skill jobs in engineering and production, right in New York State.
Looking Ahead: Scaling Solutions, Seeding Hope
While the energy storage spheres are the flagship product today, the potential of Sperra’s technology is far broader. From renewable energy anchors to coral reef restoration structures, the possibilities are vast. Their design process minimizes material use, and their marine-friendly cements can incorporate industrial byproducts like steel slag and fly ash—lowering carbon intensity while boosting local supply chains.
The next step for Sperra’s storage technology is a near-full-scale pilot—a major undertaking involving marine logistics, grid integration, and sustained funding. Sperra’s expanding team and network of partners see great promise in these innovations and their potential impact for New York and beyond.
With NYSERDA as an early champion, Sperra has gone from concept to capability, from lab to sea. The company stands today not only as a symbol of innovation, but as a model for how public-private collaboration can pave the way toward a more resilient, equitable, and sustainable energy future.
About NYSERDA Innovation & Research
NYSERDA Innovation & Research fosters a dynamic ecosystem that accelerates the development, demonstration, and commercialization of cutting-edge energy technologies. By catalyzing private investment, supporting groundbreaking research, and attracting world-class innovators to New York, NYSERDA advances statewide goals for decarbonization, resilience, and economic growth.