RAPT: Model-Predictive Out-of-Distribution Detection and Failure Diagnosis for Sim-to-Real Humanoid Robots

Deploying learned control policies on humanoid robots is challenging: policies that appear robust in simulation can execute confidently in out-of-distribution (OOD) states after Sim-to-Real transfer, leading to silent failures that risk hardware damage. Although anomaly detection can mitigate these failures, prior methods are often incompatible with high-rate control, poorly calibrated at the extremely low false-positive rates required for practical deployment, or operate as black boxes that provide a binary stop signal without explaining why the robot drifted from nominal behavior. We present RAPT, a lightweight, self-supervised deployment-time monitor for 50Hz humanoid control. RAPT learns a probabilistic spatio-temporal manifold of nominal execution from simulation and evaluates execution-time predictive deviation as a calibrated, per-dimension signal. This yields (i) reliable online OOD detection under strict false-positive constraints and (ii) a continuous, interpretable measure of Sim-to-Real mismatch that can be tracked over time to quantify how far deployment has drifted from training. Beyond detection, we introduce an automated post-hoc root-cause analysis pipeline that combines gradient-based temporal saliency derived from RAPT's reconstruction objective with LLM-based reasoning conditioned on saliency and joint kinematics to produce semantic failure diagnoses in a zero-shot setting. We evaluate RAPT on a Unitree G1 humanoid across four complex tasks in simulation and on physical hardware. In large-scale simulation, RAPT improves True Positive Rate (TPR) by 37% over the strongest baseline at a fixed episode-level false positive rate of 0.5%. On real-world deployments, RAPT achieves a 12.5% TPR improvement and provides actionable interpretability, reaching 75% root-cause classification accuracy across 16 real-world failures using only proprioceptive data.

SimTO: A simulation-based topology optimization framework for bespoke soft robotic grippers

Soft robotic grippers are essential for grasping delicate, geometrically complex objects in manufacturing, healthcare and agriculture. However, existing grippers struggle to grasp feature-rich objects with high topological variability, including gears with sharp tooth profiles on automotive assembly lines, corals with fragile protrusions, or vegetables with irregular branching structures like broccoli. Unlike simple geometric primitives such as cubes or spheres, feature-rich objects lack a clear "optimal" contact surface, making them both difficult to grasp and susceptible to damage when grasped by existing gripper designs. Safe handling of such objects therefore requires specialized soft grippers whose morphology is tailored to the object's features. Topology optimization offers a promising approach for producing specialized grippers, but its utility is limited by the requirement for pre-defined load cases. For soft grippers interacting with feature-rich objects, these loads arise from hundreds of unpredictable gripper-object contact forces during grasping and are unknown a priori. To address this problem, we introduce SimTO, a framework that enables high-resolution topology optimization by automatically extracting load cases from a contact-based physics simulator, eliminating the need for manual load specification. Given an arbitrary feature-rich object, SimTO produces highly customized soft grippers with fine-grained morphological features tailored to the object geometry. Numerical results show our designs are not only highly specialized to feature-rich objects, but also generalize to unseen objects.

A Comprehensive Experimental Characterization of Mechanical Layer Jamming Systems

Organisms in nature, such as Cephalopods and Pachyderms, exploit stiffness modulation to achieve amazing dexterity in the control of their appendages. In this paper, we explore the phenomenon of layer jamming, which is a popular stiffness modulation mechanism that provides an equivalent capability for soft robots. More specifically, we focus on mechanical layer jamming, which we realise through two-layer multi material structure with tooth-like protrusions. We identify key design parameters for mechanical layer jamming systems, including the ability to modulate stiffness, and perform a variety of comprehensive tests placing the specimens under bending and torsional loads to understand the influence of our selected design parameters (mainly tooth geometry) on the performance of the jammed structures. We note the ability of these structures to produce a peak change in stiffness of 5 times in bending and 3.2 times in torsion. We also measure the force required to separate the two jammed layers, an often ignored parameter in the study of jamming-induced stiffness change. This study aims to shed light on the principled design of mechanical layer jammed systems and guide researchers in the selection of appropriate designs for their specific application domains.

Programmable Telescopic Soft Pneumatic Actuators for Deployable and Shape Morphing Soft Robots

Soft Robotics presents a rich canvas for free-form and continuum devices capable of exerting forces in any direction and transforming between arbitrary configurations. However, there is no current way to tractably and directly exploit the design freedom due to the curse of dimensionality. Parameterisable sets of designs offer a pathway towards tractable, modular soft robotics that appropriately harness the behavioural freeform of soft structures to create rich embodied behaviours. In this work, we present a parametrised class of soft actuators, Programmable Telescopic Soft Pneumatic Actuators (PTSPAs). PTSPAs expand axially on inflation for deployable structures and manipulation in challenging confined spaces. We introduce a parametric geometry generator to customise actuator models from high-level inputs, and explore the new design space through semi-automated experimentation and systematic exploration of key parameters. Using it we characterise the actuators' extension/bending, expansion, and stiffness and reveal clear relationships between key design parameters and performance. Finally we demonstrate the application of the actuators in a deployable soft quadruped whose legs deploy to walk, enabling automatic adaptation to confined spaces. PTSPAs present new design paradigm for deployable and shape morphing structures and wherever large length changes are required.

Scalable Multi-Objective Robot Reinforcement Learning through Gradient Conflict Resolution

Reinforcement Learning (RL) robot controllers usually aggregate many task objectives into one scalar reward. While large-scale proximal policy optimisation (PPO) has enabled impressive results such as robust robot locomotion in the real world, many tasks still require careful reward tuning and are brittle to local optima. Tuning cost and sub-optimality grow with the number of objectives, limiting scalability. Modelling reward vectors and their trade-offs can address these issues; however, multi-objective methods remain underused in RL for robotics because of computational cost and optimisation difficulty. In this work, we investigate the conflict between gradient contributions for each objective that emerge from scalarising the task objectives. In particular, we explicitly address the conflict between task-based rewards and terms that regularise the policy towards realistic behaviour. We propose GCR-PPO, a modification to actor-critic optimisation that decomposes the actor update into objective-wise gradients using a multi-headed critic and resolves conflicts based on the objective priority. Our methodology, GCR-PPO, is evaluated on the well-known IsaacLab manipulation and locomotion benchmarks and additional multi-objective modifications on two related tasks. We show superior scalability compared to parallel PPO (p = 0.04), without significant computational overhead. We also show higher performance with more conflicting tasks. GCR-PPO improves on large-scale PPO with an average improvement of 9.5%, with high-conflict tasks observing a greater improvement. The code is available at https://github.com/humphreymunn/GCR-PPO.

A Framework for Dynamic Situational Awareness in Human Robot Teams: An Interview Study

In human-robot teams, human situational awareness is the operator's conscious knowledge of the team's states, actions, plans and their environment. Appropriate human situational awareness is critical to successful human-robot collaboration. In human-robot teaming, it is often assumed that the best and required level of situational awareness is knowing everything at all times. This view is problematic, because what a human needs to know for optimal team performance varies given the dynamic environmental conditions, task context and roles and capabilities of team members. We explore this topic by interviewing 16 participants with active and repeated experience in diverse human-robot teaming applications. Based on analysis of these interviews, we derive a framework explaining the dynamic nature of required situational awareness in human-robot teaming. In addition, we identify a range of factors affecting the dynamic nature of required and actual levels of situational awareness (i.e., dynamic situational awareness), types of situational awareness inefficiencies resulting from gaps between actual and required situational awareness, and their main consequences. We also reveal various strategies, initiated by humans and robots, that assist in maintaining the required situational awareness. Our findings inform the implementation of accurate estimates of dynamic situational awareness and the design of user-adaptive human-robot interfaces. Therefore, this work contributes to the future design of more collaborative and effective human-robot teams.

SoGraB: A Visual Method for Soft Grasping Benchmarking and Evaluation

Recent years have seen soft robotic grippers gain increasing attention due to their ability to robustly grasp soft and fragile objects. However, a commonly available standardised evaluation protocol has not yet been developed to assess the performance of varying soft robotic gripper designs. This work introduces a novel protocol, the Soft Grasping Benchmarking and Evaluation (SoGraB) method, to evaluate grasping quality, which quantifies object deformation by using the Density-Aware Chamfer Distance (DCD) between point clouds of soft objects before and after grasping. We validated our protocol in extensive experiments, which involved ranking three Fin-Ray gripper designs with a subset of the EGAD object dataset. The protocol appropriately ranked grippers based on object deformation information, validating the method's ability to select soft grippers for complex grasping tasks and benchmark them for comparison against future designs.

DexGrip: Multi-modal Soft Gripper with Dexterous Grasping and In-hand Manipulation Capacity

The ability of robotic grippers to not only grasp but also re-position and re-orient objects in-hand is crucial for achieving versatile, general-purpose manipulation. While recent advances in soft robotic grasping has greatly improved grasp quality and stability, their manipulation capabilities remain under-explored. This paper presents the DexGrip, a multi-modal soft robotic gripper for in-hand grasping, re-orientation and manipulation. DexGrip features a 3 Degrees of Freedom (DoFs) active suction palm and 3 active (rotating) grasping surfaces, enabling soft, stable, and dexterous grasping and manipulation without ever needing to re-grasp an object. Uniquely, these features enable complete 360 degree rotation in all three principal axes. We experimentally demonstrate these capabilities across a diverse set of objects and tasks. DexGrip successfully grasped, re-positioned, and re-oriented objects with widely varying stiffnesses, sizes, weights, and surface textures; and effectively manipulated objects that presented significant challenges for existing robotic grippers.

Whole-Body Dynamic Throwing with Legged Manipulators

Most robotic behaviours focus on either manipulation or locomotion, where tasks that require the integration of both, such as full-body throwing, remain under-explored. Throwing with a robot involves complex coordination between object manipulation and legged locomotion, which is crucial for advanced real-world interactions. This work investigates the challenge of full-body throwing in robotic systems and highlights the advantages of utilising the robot's entire body. We propose a deep reinforcement learning (RL) approach that leverages the robot's body to enhance throwing performance through a strategically designed curriculum to avoid local optima and sparse but informative reward functions to improve policy flexibility. The robot's body learns to generate additional momentum and fine-tune the projectile release velocity. Our full-body method achieves on average 47% greater throwing distance and 34% greater throwing accuracy than the arm alone, across two robot morphologies - an armed quadruped and a humanoid. We also extend our method to optimise robot stability during throws. The learned policy effectively generalises throwing to targets at any 3D point in space within a specified range, which has not previously been achieved and does so with human-level throwing accuracy. We successfully transferred this approach from simulation to a real robot using sim2real techniques, demonstrating its practical viability.

PINN-Ray: A Physics-Informed Neural Network to Model Soft Robotic Fin Ray Fingers

Modelling complex deformation for soft robotics provides a guideline to understand their behaviour, leading to safe interaction with the environment. However, building a surrogate model with high accuracy and fast inference speed can be challenging for soft robotics due to the nonlinearity from complex geometry, large deformation, material nonlinearity etc. The reality gap from surrogate models also prevents their further deployment in the soft robotics domain. In this study, we proposed a physics-informed Neural Networks (PINNs) named PINN-Ray to model complex deformation for a Fin Ray soft robotic gripper, which embeds the minimum potential energy principle from elastic mechanics and additional high-fidelity experimental data into the loss function of neural network for training. This method is significant in terms of its generalisation to complex geometry and robust to data scarcity as compared to other data-driven neural networks. Furthermore, it has been extensively evaluated to model the deformation of the Fin Ray finger under external actuation. PINN-Ray demonstrates improved accuracy as compared with Finite element modelling (FEM) after applying the data assimilation scheme to treat the sim-to-real gap. Additionally, we introduced our automated framework to design, fabricate soft robotic fingers, and characterise their deformation by visual tracking, which provides a guideline for the fast prototype of soft robotics.