A Star Trek replicator — minus the sci-fi.
A CAD file goes in. Greenlight’s software picks the material and writes the machine’s build program, then a sealed, automated machine builds the part — recording everything it did along the way.
Greenlight Industries, Inc. · Hampton, Virginia
TapeLayer™ — the machine Greenlight’s software designs for, programs, and drives.
Sealed and environmentally controlled — temperature, humidity, and cleanliness held and recorded through the whole build, exactly as the software specified it. Zero touch-labor.
Where it runs
At the customer’s, client’s, or owner’s site — never ours. On-site or remote-operated.
What it builds with
Hybrid materials mid-build — thermoset and thermoplastic in the same part, placed as engineering-grade continuous-fiber tape.
The Greenlight TapeLayer™ is not a 3D printer.
The TapeLayer™ lays engineering-grade continuous-fiber tape — the material aerospace structures are actually made of. It does not extrude filament, and its output is not a printed part.
It’s also a coordinate-axis machine: it accepts your tool surface, so real tooling geometry goes into the build volume — not just flat plates.
Design, materials, data, and manufacturing don’t talk to each other.
Three steps that usually sit with different tools, different teams — sometimes different companies entirely. Data from one step never reaches the next.
THE RESULT: SCRAP, OVERBUILD, AND A QUALIFICATION TAX ON EVERY NEW MATERIAL.
The Greenlight Loop™ Platform — every build comes home as a Digital Twin.
Four modules, one closed loop: Data → Library → Design → Digital Twin. The build code, the part, and its engineering properties travel together — then come home to make the next build smarter.
What’s real now.
LIVE Software, today
Data, Library, and Design run in beta on this site — real laminate physics, per-value provenance, honest ±bands. No hardware required.
The Closed Loop
Build telemetry and per-machine Digital Twin calibration ship with the TapeLayer™, now in development with Andrews-Cooper.
Built for the people who prove parts.
Aerospace
Primes and suppliers qualifying new material and process combinations.
Space
Flight structures where mass and traceability both matter.
Marine
Structural composites built for harsh, corrosive environments.
Ground transport
Lightweighting for range, efficiency, and cost.
Energy
Wind and other large composite structures.
Sporting goods
High-performance composites at consumer-product cost and speed.
Two levels of engagement.
There’s much more we’ve been working on behind the scenes, and we’d love to share it with you. Please consider signing either of the documents below so that we can share more of our vision.
Letter of Interest
One page, signed in a personal capacity, describing a general use case. No expiration, no obligation.
Letter of Intent
Priority wait-list position for early product access, plus direct input on product design. Not a purchase obligation.
Bring us a part.
One engineer, one candidate part, one material you wish you could quote with — that’s where every Greenlight relationship starts.
Greenlight Industries, Inc. · Delaware C-Corp · Hampton, Virginia
Two NASA patents on the TapeLayer™ · Founder: Dr. Robert Bryant, 30+ years NASA Langley.
Print this deck (⌘/Ctrl + P) to save or share it as a PDF.