Trajectory Optimization for Collision-Aware Redundant Robotic Multi-Axis Additive Manufacturing by Constrained Gradient Projection

Redundant robotic multi-axis additive manufacturing (MAAM) enables support-free and conformal fabrication, but trajectory optimization for long-horizon paths remains challenging under strict deposition-position constraints and time-varying collision constraints. This work proposes a computational framework for collision-aware trajectory optimization in redundant robotic MAAM. We first formulate nozzle-workpiece relative kinematics using a relative Jacobian, and develop a differentiable SDF-based collision model that captures fabrication-induced geometry evolution and provides optimization gradients. The deposition position is then enforced as a hard waypoint-wise equality constraint through iterative projection onto the self-motion manifold, with the loss gradient restricted to the corresponding tangent space. Experiments on an 8-DOF robotic MAAM platform with diverse long-horizon support-free and conformal toolpaths show that our method maintains a mean nozzle-position error below 10μm, reduces maximum joint jerk by up to $77.6\%$, and eliminates all sampled collision and orientation violations. Compared with the SQP-based baseline, it achieves up to a 10.2x speedup and improved convergence. Physical fabrication experiments further verify that the resulting smooth, collision-free trajectories enable successful printing of complex geometries with fewer visible deposition artifacts.

Reduced-order Neural Modeling with Differentiable Simulation for High-Detail Tactile Perception

Tactile perception is key to dexterous manipulation, yet simulating high-resolution elastomer deformation remains computationally prohibitive. Finite element methods (FEM) deliver high fidelity but demand costly remeshing, while Material Point Methods (MPM) suffer from heavy particle-memory tradeoffs. We propose a {reduced-order neural simulation framework} that couples coarse-grained MPM dynamics with an implicit neural decoder to reconstruct sub-particle tactile details from compact latent states. The framework learns a continuous deformation manifold from paired high- and low-resolution simulations, enabling physically consistent, differentiable inference. Compared to the TacIPC, our method achieves over 65\% faster simulation and {40\% lower memory usage}, while maintaining better geometric fidelity. In tactile rendering and 3D surface reconstruction, our methods further improve accuracy by 25\% and produce realistic depth images and surface mesh within a faster inference speed. These results demonstrate that the proposed reduced-order neural model enables high-detail, physically grounded tactile simulation with substantial efficiency gains for robotic interaction and optimization.