TerraForge

The Generative Simulation Platform

"Ready to Accelerate Autonomy Deployment?"

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The Autonomy Engine

Continuous Self-Learning

A closed-loop pipeline that turns real-world edge cases into "hard" synthetic training data, automating the fine-tuning of your autonomy stack.

"Stop training on empty miles. Start training on the edge."

Traditional autonomy development stalls because real-world data is expensive to collect and rarely captures the dangerous "long-tail" events that break your AI.

Cognitron PhysAI replaces this linear process with an Active Learning Loop. By continuously comparing your model's predictions against real-world outcomes, we identify exactly where your AI is weak. Our platform then automatically generates "Adversarial Synthetic Data"—specifically crafted, high-difficulty scenarios that target those weaknesses.

Model Registry
1

Synthetic Bootstrapping

The Cold Start

2

Active Deployment

Data Harvesting

3

Real-to-Sim

Compare & Correct

4

Adversarial Amplification

The "Harder" Data

Stage 1: Synthetic Bootstrapping

Physics-Driven Generation

We ingest your vehicle model, sensor suite, Operational design domain and to generate millions of baseline training frames. Our generative world models apply domain randomization—shifting weather, lighting, and soil textures—to create a robust initial policy without a single hour of real-world operation.

Stage 2: Active Deployment & Harvesting

Targeted Data Collection

Deploy the model to the field. As your machines operate, our system automatically flags and uploads 'low-confidence' events—moments where the AI was uncertain or the operator had to intervene—filtering out terabytes of empty data.

Stage 3: Real-to-Sim Reconstruction

Automated Root Cause Analysis

The system ingests real-world failure logs and automatically reconstructs the exact scenario in simulation. We compare the model's prediction against the operator's actual ground truth to mathematically identify why the failure occurred.

Stage 4: Adversarial Amplification

Adversarial Fine-Tuning

This is where we close the gap. The platform takes that single real-world failure and uses Generative AI to spawn 10,000 'harder' variations—adding blinding dust, sensor noise, or slippery mud. The model is fine-tuned on this hyper-targeted 'Gold' dataset to master the edge case.

Synthetic Data Generation - Multiple Environment Variations

Simulation-First CI/CD

The Release Confidence Engine

Every code change is validated against thousands of virtual edge cases before touching physical hardware. Deploy to simulation first, test in countless unique scenarios with real physics, then confidently release to the field.

CI/CD Pipeline for Physical AI
10,000+ Edge Cases Tested Per Build
60% Reduced Testing Costs
24hr Model Retrain Cycle
99% Bugs Caught in Sim

Deploy to Simulation First

Test any code change in a physics-accurate virtual environment before it ever reaches physical assets. No risk of damaging expensive machinery.

Infinite Scenario Testing

Automatically generate unique situations—weather variations, terrain changes, sensor failures, sudden obstacles—that would be impossible to stage in reality.

Safety Certification

Generate the artifacts and logs required for ISO 19014 functional safety certification automatically. Simulation as a legal compliance asset.

Active Learning Loop

When real-world anomalies occur, recreate them in simulation, generate thousands of variations, and retrain models within 24 hours.

Hostile Environment Sensors

Real offroad

Clean-air simulations create brittle vision models. TerraForge models the chaotic, particulate-dense environments of construction sites where standard sensors fail.

Sensor Degradation Comparison - Clean vs Hostile Environment
Volumetric Dust and Fog Simulation

Volumetric Dust & Fog

Physics-based Mie scattering simulates lidar backscatter from dust clouds and signal attenuation in fog or rain conditions.

Camera Lens Soiling Simulation

Camera Lens Soiling

Model physical degradation like mud splatter, rain, fog on lenses. Test sensor health monitoring and autonomy stack performance under adversarial conditions" monitoring and automated cleaning protocols.

Rain and Snow Effects Simulation

Rain & Snow Effects

Simulate precipitation impact on all sensor types—camera occlusion, lidar noise, and GPS signal degradation.

RTX Lidar Physics Simulation

RTX Lidar Physics

Path-traced lidar simulation captures true photon physics—beam divergence, multi-path reflections, and material-specific returns.

Multi-Agent Fleet Intelligence

The Site Brain

Beyond individual machine control—orchestrate entire fleets. Excavators and haul trucks learn to collaborate, negotiate, and optimize project workflows through shared intelligence.

Multi-Agent Fleet Coordination at Construction Site

Fleet Choreography

  • Dynamic truck positioning relative to excavator swing arcs
  • Synchronized dual-lift operations for heavy loads
  • Deadlock resolution in constrained spaces
  • Learned negotiation logic for right-of-way

Site Orchestration

  • Mixed fleet interaction (autonomous + human vehicles)
  • Real-time cycle optimization across zones
  • Proactive re-routing during congestion
  • VDA5050 interoperability with Fleet Management

Economic Optimization

  • Test fleet compositions before purchase
  • Predict fuel burn per ton moved
  • Simulate entire project timelines
  • Optimal loader-to-truck ratios
Excavator Digital Twin - Physical vs Holographic

Ready to Bridge the Reality Gap?

Accelerate your autonomy roadmap by 12-18 months with physics-accurate simulation.