NLiPsCalib: An Efficient Calibration Framework for High-Fidelity 3D Reconstruction of Curved Visuotactile Sensors

Tactile sensing plays a key role in enabling dexterous and reliable robotic manipulation, but realizing this capability requires substantial calibration to convert raw sensor readings into physically meaningful quantities. Despite its near-universal necessity, the calibration process remains ad hoc and labor-intensive. Here, we introduce 3D Cal, an open-source library that transforms a low-cost 3D printer into an automated probing device capable of generating large volumes of labeled training data for calibrating vision-based tactile sensors. 3D Cal also provides an end-to-end, user-friendly pipeline for training custom convolutional networks to produce high-quality depth reconstructions. Using 3D Cal, we systematically explore the relationship between training data volume and spatial reconstruction performance on two commercially available sensors, DIGIT and GelSight Mini, and derive practical, empirically-grounded guidelines for calibrating these sensors. Finally, we demonstrate depth reconstruction performance on the DIGIT and GelSight Mini comparable to state-of-the-art methods, achieving average reconstruction errors of 156 $\mathrm{μm}$ and 205 $\mathrm{μm}$ on unseen objects, respectively. By automating tactile sensor calibration, 3D Cal can accelerate tactile sensing research, simplify sensor deployment, and facilitate the integration of tactile sensing in robotic platforms.

Curved tactile fingertips for dexterous manipulation must resolve fine contact geometry, distinguish normal and tangential loads, and capture transient signals. Existing curved vision-based tactile sensors struggle to combine accurate 3D reconstruction, three-axis force estimation, and high-speed processing in a compact form. This article presents FasTac, a curved vision-based tactile sensor integrating multispectral photometric stereo, dynamic-convolution force estimation, and hardware acceleration on a field-programmable gate array (FPGA). Single-image-sensor simultaneous multispectral imaging provides spatially aligned observations for robust surface normal estimation, followed by boundary-prior fast Poisson depth reconstruction. HyperForce uses position-aware dynamic convolution to model the spatially nonuniform mechanical response of curved elastomers and estimate three-axis forces. The complete image-to-normal-force pipeline is deployed on an FPGA. Experiments show that near-infrared (NIR) illumination and the boundary prior decrease depth mean absolute error (MAE) from 0.2730 mm to 0.0415 mm; HyperForce achieves normalized mean absolute error (NMAE) values of 2.74% and 2.39% for normal and shear forces, respectively; and FPGA deployment shortens processing latency from 3.26 ms on the GPU to 1.09 ms. Multi-object reconstruction, feedback grasping, and vibration measurement validate fine geometric perception, stable force feedback, and dynamic contact sensing.

Vision-based tactile sensors are a popular solution for capturing rich contact surface geometry. However, to obtain high-detail contact surface normals and depth, it is necessary to calibrate the sensor by physically pressing a probe with known geometry against the sensor elastomer and mapping tactile images onto the ground truth probe's shape. This approach does not scale across different tactile sensors, and the calibration effort can be complex depending on the sensor shape and optical system. Instead, we propose a calibration-free procedure for the estimation of contact surface normals using Universal Photometric Stereo neural networks. In a series of real-world experiments, we evaluate our approach on 3 sensors with different optical systems, demonstrating that universal methods are a suitable approach for estimating surface normals at the contact patch from tactile images, thereby alleviating the need for tactile sensor calibration. Controlled experiments with a metal ball show that universal methods match the calibrated method, with a mean angular error of $6.56^{\Large\circ}$. We show that the proposed framework recovers high-frequency surface details of objects with natural textures, achieving an overall mean angular error of $10.66^{\Large\circ}$. Universal method robustly recovers the contact surface normals captured with dome-shaped Digit 360, achieving a low angular discrepancy of $10.18^{\Large\circ}$ relative to the calibrated baseline. This experiment demonstrates that with sufficient illumination settings surface normals could be estimated using a model trained solely on synthetic data. By providing a unified representation of contact surfaces across different vision-based tactile sensor designs, Universal Photometric Stereo neural networks lay the foundation for transferable tactile perception across sensors.