CAD-Driven Co-Design for Flight-Ready Jet-Powered Humanoids

This paper presents a CAD-driven co-design framework for optimizing jet-powered aerial humanoid robots to execute dynamically constrained trajectories. Starting from the iRonCub-Mk3 model, a Design of Experiments (DoE) approach is used to generate 5,000 geometrically varied and mechanically feasible designs by modifying limb dimensions, jet interface geometry (e.g., angle and offset), and overall mass distribution. Each model is constructed through CAD assemblies to ensure structural validity and compatibility with simulation tools. To reduce computational cost and enable parameter sensitivity analysis, the models are clustered using K-means, with representative centroids selected for evaluation. A minimum-jerk trajectory is used to assess flight performance, providing position and velocity references for a momentum-based linearized Model Predictive Control (MPC) strategy. A multi-objective optimization is then conducted using the NSGA-II algorithm, jointly exploring the space of design centroids and MPC gain parameters. The objectives are to minimize trajectory tracking error and mechanical energy expenditure. The framework outputs a set of flight-ready humanoid configurations with validated control parameters, offering a structured method for selecting and implementing feasible aerial humanoid designs.

Unified Multi-Rate Model Predictive Control for a Jet-Powered Humanoid Robot

We propose a novel Model Predictive Control (MPC) framework for a jet-powered flying humanoid robot. The controller is based on a linearised centroidal momentum model to represent the flight dynamics, augmented with a second-order nonlinear model to explicitly account for the slow and nonlinear dynamics of jet propulsion. A key contribution is the introduction of a multi-rate MPC formulation that handles the different actuation rates of the robot's joints and jet engines while embedding the jet dynamics directly into the predictive model. We validated the framework using the jet-powered humanoid robot iRonCub, performing simulations in Mujoco; the simulation results demonstrate the robot's ability to recover from external disturbances and perform stable, non-abrupt flight manoeuvres, validating the effectiveness of the proposed approach.