A safe 302 pound foam auto getting 100+ miles per gallon is no longer a dream.  Lon Ballard used 90% reinforced foam construction to offer both pedestrian and passenger protection.   It speeds to over 70 mph AND it is unsinkable….it floated stable like a boat when it went into the ocean March 16, 2009.   The Spira team hopes foam will revolutionize autos and motorcycles, the way Crocs and flip-flops have revolutionized shoes and sandals with foam.  

Lon Ballard has invented a way to bring safety to both pedestrians and passengers with a revolutionary foam, super light vehicle.  .  Over 6 inches of SOFT foam on all sides provides an estimated 1 billion tiny foam air bags for enhanced SAFEty.  The exterior and interior of the auto is primarily composed of foam for pedestrian and passenger protection.  Its 30 pound, foam composite top is easily removed to have a SEXY convertible.  SOFT, SAFE, SEXY is Spira’s motto. 

Car design has focused on passenger safety while neglecting pedestrians, motorcyclists, and bicyclists.   Pedestrian, bicycle, and motorcycle accidents and fatalities need more consideration.  Some studies show that about one half the auto accident fatalities are pedestrians in urban areas and developing countries.  See the chart below from www.prb.org:

Proportion of Road Users Killed in Various Modes of Transport
As A Percent of All Fatalities, Selected Countries

*Note: Dates for above data vary according to city and country: Thailand, 1987; Malaysia, 1994; and United States, 1995.

Source: Dinish Mohan, "Traffic Safety and Health in Indian Cities," in Journal of Transport and Infrastructure no. 9 (2002).

This chart shows that 88 percent of road kills are not car passengers in Thailand but pedestrians, bicyclists, and motorcyclists.  Similarly in Malaysia 81 percent of vehicle deaths are not car passengers.  This is typical for the 3 Billion people in Asia.  Many motorcycles in Asia are used for work and some have a side car attached to them for carrying people, children, and supplies.  The foam Spira is designed to increase safety for the pedestrian, bicyclist, motorcyclist, and the passenger.  Car design has focused on passenger safety and not the total accident and death rate
Spira’s patent pending technology can revolutionize the way vehicles are designed and produced.   Spira uses reinforcing fibers and aluminum to provide a strong a protective cage covered with soft foam on both the outside and inside.  Foam can replace steel in cars for a more cushioned impact just as foam has replaced leather soles on most shoes and sandals.  Foam protection on the outside of autos is needed because over half of vehicle deaths in large cities and developing countries are pedestrians and motorcyclists.

Spira is a low cost, simple 3 wheel configuration that achieves 100+mpg with an 110cc power plant.   Spira is designed to use interchangeable off the shelf reliable motorcycle power plants and parts in initial production.  This sleek utilitarian vehicle is a great choice for any commuter along with being a safe replacement for a motorcycle with all weather protection.  Its patent pending technology can make any vehicle safer, more efficient and have less environmental impact.  It is hard to believe this 8 feet long x 5 feet wide x 52 inches tall auto which seats tow weighs only 302 pounds.

Spira is seeking global/ local suppliers, dealers and manufacturers to share in our dream of producing efficient, light, safe, vehicles.  Spira is starting limited production at the Detroit of the East in Thailand.  Our business plan is to license production world wide to get high local content and to speed market access. 

The pointed front decreases air resistance and makes for a small target.  In a crash it is best to deflect and roll as in Judo.  The design choices were to fit a safe yet efficient shape around the people and mechanics.  Styling came secondary to achieve a sleek efficient shape while using light weight, flexible, energy adsorbing, materials.  Thought was given to what will happen to the components in a crash.   Tow of the first vehicles will be crash tested.

The millions of air bags in foam offer crash protection and light weight.  Some foams are very strong and now are used to replace metal and plastics.  40 years ago who would think that nearly every one would have foam shoes.  First came flip flops and then came Crocs.  It is now hard to find leather or solid rubber soles.

Up until now drivers had to choose between a big heavy gas hog and smaller, less safe, yet more fuel efficient cars.  The inventor has tried to create a safe, ultra light, and ultra efficient design.  The body is mostly foam with fiberglass and aluminum for reinforcement.  The 6 inches of foam on all sides will give both passengers and pedestrians protection.  The sleek shape similar to a jet or space shuttle keeps down wind resistance. 

The first prototype chassis used hand laminated foam employing fiberglass layered within the foam.  Preproduction molds are being made to automate the chassis production.  The goal of the first production design is to keep it safe and simple.  Spira hopes to be a safe, cheap replacement for the millions of dangerous motorcycles in the world.  Being aerodynamic and light, Spira achieves the same fuel consumption as motorcycles.  The use of a reliable production motor scooter power plant that attaches with 2 bolts keeps maintenance simple.  At 302 pounds Spira weighs only 50 pounds more than the 110cc motorcycle. Newer more efficient and powerful engines and electric drivers are being tried.

The 100+ mpg and low cost should entice drivers to take a step down from their luxury vehicles to save fuel and help the environment.  In the future this patent pending foam technology can be used in all size of vehicles to improve safety and fuel consumption.  The Spira team is seeking manufactures/engineers as partners to buy franchises to produce, help design, and sell vehicles through out the world.  

Every once in a while innovation will spark revolutionary improvements in an industry and our lives.  Spira hopes the safety and light weight of foam will make our world safer and greener.  The foam chemical components can be made from renewable sources such as soybeans.