Prior Availability in Industrial Visual Sim-to-Real: A Review of CAD-Guided and CAD-Unavailable Regimes

Industrial visual sim-to-real is often described as transferring from synthetic images to real images, but industrial deployment usually involves a broader mismatch between available evidence and required decisions. A system may be built from CAD renderings, simulated RGB-D observations, normal reference images, synthetic defects, pretrained feature spaces, or language prompts, yet deployed under different sensors, lighting, materials, fixtures, calibration, production variation, and rare defect modes. This review reframes industrial visual sim-to-real as a domain-gap problem organized by prior availability. We distinguish CAD-available settings, where explicit object geometry can support rendering, calibration, pose estimation, segmentation, and test-time geometric verification; CAD-unavailable settings, where geometry is replaced by normal-reference appearance, feature distributions, teacher-student residuals, synthetic anomaly assumptions, foundation features, or vision-language priors; and boundary-prior settings, where approximate models, templates, reference views, or semantic correspondences preserve only part of the CAD role. This framing connects CAD-based detection and 6D pose-estimation literature with industrial anomaly and surface-inspection literature that is usually reviewed separately. To make the taxonomy concrete, we use empirical anchors on T-LESS/BOP, MVTec AD, and VisA. The anchors show that CAD render count alone does not close transfer; source-distribution design, detector capacity, and small real calibration can matter more. They also show that CAD at test time creates a distinct verification channel through mask, pose, and depth consistency, whereas CAD-unavailable inspection relies on calibrated normality and feature deviation. The review therefore argues against a single cross-task leaderboard and instead asks what prior grounds the deployment decision.

MPC as a Copilot: A Predictive Filter Framework with Safety and Stability Guarantees

Ensuring both safety and stability remains a fundamental challenge in learning-based control, where goal-oriented policies often neglect system constraints and closed-loop state convergence. To address this limitation, this paper introduces the Predictive Safety--Stability Filter (PS2F), a unified predictive filter framework that guarantees constraint satisfaction and asymptotic stability within a single architecture. The PS2F framework comprises two cascaded optimal control problems: a nominal model predictive control (MPC) layer that serves solely as a copilot, implicitly defining a Lyapunov function and generating safety- and stability-certified predicted trajectories, and a secondary filtering layer that adjusts external command to remain within a provably safe and stable region. This cascaded structure enables PS2F to inherit the theoretical guarantees of nominal MPC while accommodating goal-oriented external commands. Rigorous analysis establishes recursive feasibility and asymptotic stability of the closed-loop system without introducing additional conservatism beyond that associated with the nominal MPC. Furthermore, a time-varying parameterisation allows PS2F to transition smoothly between safety-prioritised and stability-oriented operation modes, providing a principled mechanism for balancing exploration and exploitation. The effectiveness of the proposed framework is demonstrated through comparative numerical experiments.