A Deployment Case Study in Robotic Apparel Automation: Digital Twin Integration, Interoperability, and Workforce Enablement

Despite steady advances in flexible automation in sectors such as electronics and automotive manufacturing, apparel automation remains challenging because fabrics are deformable and difficult to manipulate with robots. This paper presents a deployment-oriented case study of a robotic sewing system for denim manufacturing, emphasizing the system-level integration required for practical adoption. At the engineering level, a digital thread module parses DXF production drawings into process parameters and executable robot trajectories, reducing manual programming effort and enabling rapid re-targeting across sewing operations. In parallel, a digital twin of the workcell is used during pre-deployment to validate reach and clearance, refine layout and sequencing, evaluate operator access, and assess cycle-time compatibility with upstream and downstream tasks, thereby reducing commissioning risk. At deployment, the system integrates a collaborative robot with conventional sewing equipment, welding, suction fixtures, and machine-level controllers through an interoperability layer. Runtime monitoring and verification, including seam monitoring, collision checking, and trajectory-level validation, improve robustness under environmental variability, while operator-facing training and guidance tools support setup, troubleshooting, and technology adoption. Two staged factory deployments on denim shorts, covering 2D pocket operations and 3D garment-shaping seams, show that digital-twin-based validation, digital-thread-driven task generation, interoperability, runtime verification, and operator training are important for scaling robotic apparel automation.

GrowSplat: Constructing Temporal Digital Twins of Plants with Gaussian Splats

Accurate temporal reconstructions of plant growth are essential for plant phenotyping and breeding, yet remain challenging due to complex geometries, occlusions, and non-rigid deformations of plants. We present a novel framework for building temporal digital twins of plants by combining 3D Gaussian Splatting with a robust sample alignment pipeline. Our method begins by reconstructing Gaussian Splats from multi-view camera data, then leverages a two-stage registration approach: coarse alignment through feature-based matching and Fast Global Registration, followed by fine alignment with Iterative Closest Point. This pipeline yields a consistent 4D model of plant development in discrete time steps. We evaluate the approach on data from the Netherlands Plant Eco-phenotyping Center, demonstrating detailed temporal reconstructions of Sequoia and Quinoa species. Videos and Images can be seen at https://berkeleyautomation.github.io/GrowSplat/

Robotic Defect Inspection with Visual and Tactile Perception for Large-scale Components

In manufacturing processes, surface inspection is a key requirement for quality assessment and damage localization. Due to this, automated surface anomaly detection has become a promising area of research in various industrial inspection systems. A particular challenge in industries with large-scale components, like aircraft and heavy machinery, is inspecting large parts with very small defect dimensions. Moreover, these parts can be of curved shapes. To address this challenge, we present a 2-stage multi-modal inspection pipeline with visual and tactile sensing. Our approach combines the best of both visual and tactile sensing by identifying and localizing defects using a global view (vision) and using the localized area for tactile scanning for identifying remaining defects. To benchmark our approach, we propose a novel real-world dataset with multiple metallic defect types per image, collected in the production environments on real aerospace manufacturing parts, as well as online robot experiments in two environments. Our approach is able to identify 85% defects using Stage I and identify 100% defects after Stage II. The dataset is publicly available at https://zenodo.org/record/8327713