Welcome to

Project Zephyr No Background Cream:Orang

Foamblock's electric-car-building STEAM experience. All the benefits of the scratch build, with the efficiency of a kit-build.

We created Project Zephyr with the goal of helping young people find an activity that suits them, that they love and can do passionately. A person who finds this provides themselves with sustainable living and the world with a healthy, happy, productive individual 

We've built on years of educational experience and research focusing on answering one of students most important questions "What do I do after school?". Project Zephyr sends students aged 12+ on a learning journey where they have the opportunity to delve deep into STEAM while also learning about business, law, marketing, teamwork, leadership and more.


Project Zephyr splits into two parts, the practical, and the social, where students together with staff discuss their discoveries during the practical part. Foamblock provides institutions with our custom-designed mapping algorithm to aid students in discovering their individual path after school. 

The entire experience is student-led and can be done anywhere an institution has the staff able to ensure students safety when using basic DT workshop tools. Project Zephyr comes with all the hardware, as well as all the necessary teaching materials for institutions to put this into practice efficiently with minimum setup time

We believe that Project Zephyr can truly change the way a student learns and prepares for life after school.

Project Zephyr video A

Project Zephyr in Numbers

- Six years of successful operation

- 8 cars built 

- Group Sizes reccomended up to 5/car


- 1 staff member/2 cars 

- 60sqm workshop space  / 2 cars 

- 1-1.5 academic years to do *

- Over 100km/h top speed**

- 205Nm of torque 

* 2h/week - estimate given is upper bound, can be <1y 

**Speed can be limited electronically

Infinite diversity

To achieve our goals we said from the beginning "this cannot be a kit car" and we stuck to that. By having a kit, you restrict the students options, their depth of thinking and opportunity to problem solve.


By having a full-scratch build, you cannot offer it to inexperienced students restricting your impact. 

Project Zephyr must be practical across a large range of abilities and technical equipment. 

We combined the kit concept with the scratch build concept and took the best from both worlds and added some magic of our own. 

You don't have to worry about unknown extra costs, complicated extra tools or specialised staff.  Everything you need comes together with Project zephyr and you will get an awesome teaching experience and insanely fun end result with each group that tries it. 


Environmentally conscious 

Project Zephyr was built to be over 70% reusable as-is after the first build. It can be disassembled for use by the next student group.  Over 65% of Project Zephyr can be re-used as-is for 5+ years*.


As a result, Project Zephy becomes incredibly cost effective due to the low yearly running costs allowing you to get a quick ROI. 


Of the less than 35% which cannot be re-used, over 90% is recyclable or biodegradeable**.

Due to this reusability and the relatively quick ROI this offers of ~2-3 years, Project Zephyr has minimal impact on your budget over time. 

*reusability is subject to the end-users application of the product.

**recyclability depends on the recycling facilities in your local area. 


If, for example, you decide to educate your students on the mechanics of car crashes to teach vehicle safety by smashing your vehicle (with a dummy driver) into brick walls at top speed, less will be re-useable. 

What's in the box?

Based on your needs, you will receive everything you need to build your car:

Raw materials - Pipes, bars, sheet metal etc.

Basic components - Brakes, Wheels, Steering wheel etc. 

Assembly equipment - Nuts and bolts etc. 

Teaching materials, staff training, step-by-step how-to video guides and more. 
Everything you need to know to run Project Zephyr within your institution. 

What's in the box to the left? That's a car built by students from the British School of Bucharest.

What do I need to do this?

"If you can't explain it simply, you don't understand it well enough" - Albert Einstein. 

A room you can use as a workshop ~30sqm/car. 

Basic power tools: Drill, Jigsaw etc

Hand tools: A rubber mallet, Hacksaws, Wrenches, Allen keys etc.

An individual that can safely supervise and teach students using the tools mentioned above. 

Staff Training  

Surely you would need an automotive engineer to teach this right? 

If you have one thats fantastic, however it is not a requirement. Project Zephyr comes with a full package of training materials.


As long as your staff can ensure the students safety in the workshop we provide everything that you need in detailed videos so that you can learn the A-Z on Project Zephyr. 

The videos can also be selectively shown to students rectly should you wish to do so.