AI simulation for physical AI

Describe the world. AI finds where your robot fails.

Forge's AI turns plain English into a physically real twin of your site, robot and sensors. It drafts the scenarios and edge cases and runs the ones you approve, so failures show up in simulation, before deployment. Your engineers stay in charge of what gets tested and what counts as a pass; the AI does the setup work that used to need a dedicated simulation team.

  1. 01 · You Describe it in words or video
    “Six aisles, four dock doors, staging by Dock 4. The robot must stop for people.”or a site video
  2. 02 · AI Drafts the world
  3. 03 · AI Proposes the tests
  4. 04 · You Get the verdict

    52 pass
    2 fail

    Found before deployment
No simulation build-out Physically real robot & sensors Dozens of edge cases from one scenario Evidence you can replay

The problem

Robots don't fail in the demo. They fail in the real world.

A leaning pallet, a person stepping into the path, light that washes out the camera. Today these moments turn up one at a time, months into a field pilot, with people nearby.

01Months

of field pilots before a fleet can scale

Every edge case waits for the real world to produce it.

02Specialists

to build a realistic simulation

Scenes, robot models, sensor calibration and test code all need scarce skills.

03Untested

the edge cases nobody wrote

Each variation is built by hand, so most are never tried.

04Silent

regressions with every update

What worked last quarter quietly breaks in the field.

One platform

Simulation for the full physical-AI lifecycle.

Develop, evaluate, and generate data in one place — anchored on the piece the others exist to serve: an independent verdict you can stand behind.

Develop

Build against a real twin

Harden your driving policy against a calibrated digital twin of the site it will actually deploy into.

Where we start Evaluate

The independent verdict

Prove function, safety, and benchmark in one loop — a graded, standards-traceable result you can show a buyer.

Generate

Synthetic data & coverage

Turn every run into labeled, ground-truth scenario data — the long-tail coverage a real floor can't give you.

// 01 AI builds your world

Your site, your robot, its sensors. Physically real, without the simulation build-out.

Describe the site or import a video. Import your robot or pick an existing one. Forge's AI lays out the scene, sets up the robot, then places and calibrates its sensors, so the robot moves and sees in simulation the way it does in real life. You review each step and correct anything the AI got wrong.

forge › scene.build
YouA warehouse with four dock doors on the north wall, six aisles and a staging area beside Dock 4.

Building from the asset library…

142 assets placed Areas named Physics-ready
Youmy-robot.urdfimported
  • Body & payloadmass and centre of gravity
  • Drive & steeringwheel friction tuned
  • Brakesresponse delay matched
  • Sensors found1 LiDAR · 1 camera
Braking: real robot vs simulationAI tuned
real robotbeforeafter tuning

Calibrating to the real sensors

LiDARcalibrated
range 0.1–30 m · noise ±2 cm
Front cameracalibrated
lens · exposure · glare response
Mountingmatched
height 1.20 m · tilt −4°
Calibrated to what the real robot sees

// 02 AI writes your tests, runs and debugs them

Say what matters. AI drafts the test and suggests the edge cases you'd miss.

In the world you just built, describe the situation in plain English. Forge's AI turns it into a runnable scenario, widens it with the conditions and edge cases the real world throws at robots, and runs the set you approve.

forge › scenario.draft
YouMake sure the robot stops for people stepping into its path in Aisle A-7.

AI drafted the scenario

  1. The robot drives down Aisle A-7 at speed.✓ accepted
  2. A person steps out from behind the racking.✓ accepted
  3. The robot stops at least 0.50 m from the person.✓ accepted
Which end of Aisle A-7 does the person step out from?
Dock endStaging end

AI suggested edge cases for this scenario

  • Person carrying a box that hides their legsharder for the camera to recognise+ added
  • Sun glare through an open doorwashes out the front camera+ added
  • Wet floor near the aisle endlonger braking distance+ added
speed0.81.21.6 m/s
lightnormallowglare
noiseclean±2 cm
54runs from one scenario
speed0.8 m/s1.2 m/s1.6 m/s
lightnormallowglare
Run 1 of 9one run at a time
Run 6 · 1.2 m/s · glare

Stopped at 0.28 m. Needed 0.50 m. Fail.

−0.22 m
0.81.21.6 normal low glare

7 pass · 2 fail, found before anyone was at risk.

Root cause from ROS messages

/camera/front exposure saturated for 340 ms after the door opened → detection came 0.6 s late → braking started at 1.1 m instead of 1.7 m.

Trend same failure in 3 of the last 5 releases under glare

Every run keeps the robot, site and settings that produced it, ready to replay for your safety review.

robot v3.2 · site DC-3 · seed 4127

// 03 Why Forge

Built to give you an honest read on your robot.

Your team, not a simulation team

AI handles the scene, robot, sensors and scenario drafting. Your engineers review, approve and decide what counts.

Physically real

Calibrated robot movement and sensors in a physics-based twin, so what happens in Forge is a faithful predictor of what happens on site.

Won't bend a safety test

When a detail is unclear, the AI asks. When a change would alter what the test means, Forge says so.

Evidence, not a green tick

Every result carries the measurement behind it and replays deterministically, ready for your safety review.

// 04 Solutions

One proving ground. Every kind of robot.

The workflow is the same whatever moves: describe the world, let AI draft the world and the tests, approve them, read the verdict. We start where the stakes are highest and the floor is busiest.

Available now

Forklifts

Autonomous and assisted forklifts in warehouses, distribution centres and docks: pedestrians, loads at height, trailers and mixed traffic.

Explore the forklift solution
Coming soon

Mobile robots

AMRs moving goods between stations, shelves and people.

Coming soon

Humanoids

General-purpose robots working alongside people.

Coming soon

Drones

Inspection and inventory flights indoors and out.

Coming soon

Agricultural robots

Field robots facing terrain, weather and crops.

// 05 Who it's for

Three sides of the same deployment.

Will this release hold up at every customer's site?

Recreate each customer's site with AI, run every release against the situations they actually face, and catch what broke before they do.

  • Catch regressions between software releases
  • Walk into pilots with evidence, not promises
  • Start from ready-made safety scenario suites
Book a demo for robot makers

Book a demo

Bring us the scenario that keeps you up at night.

We'll build your world and run it in Forge with you in a 30-minute session.

Prefer email? hello@fireloop.ai

Thanks, we'll be in touch within one working day.

We only use your details to arrange the demo.