Design, manufacturing, and materials data — one closed loop.
Composites are designed, simulated, and manufactured in three disconnected worlds. The Greenlight Loop™ platform couples them: four modules that carry a material from datasheet to design to build — and carry the as-made results back.
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The return path is the product.
Each module works standalone. The compounding value is the return path: every part the TapeLayer™ builds sends structural data married to material data back into the customer’s own library.
FIG. 1 — the Loop™ platform. The return path is the product.
Software beta today Ingest, Library, and Design run today in beta. The as-made return path activates with each TapeLayer™ machine.
Get the data in, keep its pedigree, design with it, and let the machine teach the model.
Datasheets & Test Reports → Structured, Cited Data
Every value keeps its source — document, page, vendor-stated or Greenlight-assumed. Nothing enters the library without a citation.
- Per-value provenance: source document, page, vendor-stated vs. assumed uncertainty.
- Vendor-silent values carry the disclosed default of ±10% — marked, never hidden.
The Provenance-Carrying Materials Database
Organized around what the engineer is trying to do, not around vendor catalogs — filter by property, material type, temperature range, and cost.
- Property rows bracketed at −20 °C / RT / +120 °C, with min/max service-temperature filters.
- Every value labeled by reliability: measured / model-derived / assumed.
- Private save spaces: uploaded materials and as-made results are private by default, shared only if the customer chooses.
Targets → Ply-by-Ply Layup With Explicit Confidence
Works in both directions — targets-first or material-first — and always outputs a ply-by-ply stack with the confidence stated on its face.
- Confidence floor: no recommendation below 90% — the honest answer shows instead.
- Integer iteration counts, rounded up; out-of-domain cases are labeled “needs FEA (finite element analysis)” rather than a fabricated number.
Per-Machine As-Made Calibration
Every TapeLayer™ carries a digital twin tuned to that machine’s own sensors, actuators, and environment.
- Build telemetry — temperature, humidity, speed, position, tape tension — the Step-1 record the industry discards.
- As-made properties flow back to Library, married to the part’s structural data.
How a value looks in the product.
Provenance is a visual system, not a footnote. Vendor-stated values print in ink, assumed values in blue with the assumption disclosed, as-made values in green. Every value carries an explicit ±.
| Property | Value | Reliability | Provenance |
|---|---|---|---|
| Tensile modulus E₁ | 161 GPa ±2.3% (23.4 Msi) | measured | vendor-stated · datasheet p.4 |
| Transverse modulus E₂ | 8.96 GPa ±10% assumed (1.30 Msi) | assumed | vendor silent · default applied |
| In-plane shear G₁₂ | 4.69 GPa ±2.1% (0.680 Msi) | measured | as-made · machine + build ID |
Values shown are representative published values for this material class, used here to demonstrate the provenance treatment. See Proof for the full policy.
Why this compounds.
Greenlight is the first to productizea device-coupled as-made data flywheel. Each machine’s twin is tuned to that machine’s own sensors, actuators, and environment, so raw twins don’t transfer across machines — but the network learns priors that speed every new machine’s calibration, and the cold-start cost decays as the fleet grows. The dataset a customer builds on their machine is theirs, it deepens with every build, and it can only be written by a Greenlight machine.
The industry designs from datasheet allowables that ignore Step 1— who laid the material up, how, and in what environment. The Loop™ platform is built around recording Step 1 and linking it to the measured outcome. That link is what makes the data worth more every time the loop closes.
Coupled to the device — by design
Greenlight software is not sold standalone. Every module is coupled to a specific TapeLayer™ machine: the twin is calibrated to that machine, and the as-made data is generated by it. That coupling is the answer to “why won’t this run on other machines?” — it isn’t designed to, and that is the point.
See it run.
The demo walks a structural engineer’s composite bracket through all six stages of the loop — real laminate physics, honest bands, provenance on every number.
Greenlight Industries, Inc. · Delaware C-Corp · Virginia, USA — TapeLayer™: two NASA patents, Bryant sole inventor.