EvoGymCM: Harnessing Continuous Material Stiffness for Soft Robot Co-Design

Soft robots achieve functionality through tight coupling among geometry, material composition, and actuation. As a result, effective design optimization requires these three aspects to be considered jointly rather than in isolation. This coupling is computationally challenging: nonlinear large-deformation mechanics increase simulation cost, while contact, collision handling, and non-smooth state transitions limit the applicability of standard gradient-based approaches. We introduce a smooth, low-dimensional design embedding for soft robots that unifies shape morphing, multi-material distribution, and actuation within a single structured parameter space. Shape variation is modeled through continuous deformation maps of a reference geometry, while material properties are encoded as spatial fields. Both are constructed from shared basis functions. This representation enables expressive co-design while drastically reducing the dimensionality of the search space. In our experiments, we show that design expressiveness increases with the number of basis functions, unlike comparable neural network encodings whose representational capacity does not scale predictably with parameter count. We further show that joint co-optimization of shape, material, and actuation using our unified embedding consistently outperforms sequential strategies. All experiments are performed independently of the underlying simulator, confirming compatibility with black-box simulation pipelines. Across multiple dynamic tasks, the proposed embedding surpasses neural network and voxel-based baseline parameterizations while using significantly fewer design parameters. Together, these findings demonstrate that structuring the design space itself enables efficient co-design of soft robots.

Soft robots promise inherent safety via their material compliance for seamless interactions with humans or delicate environments. Despite progress, the field struggles to balance task-specific performance with broader factors like durability and manufacturability--a difficulty that we find is compounded by traditional sequential design processes with their lack of feedback loops. In this perspective, we review emerging co-design approaches that simultaneously optimize the soft robot's body and brain, enabling the discovery of unconventional designs highly tailored to the given tasks. Their adoption is limited by narrow objectives, gaps between simulated and real performance, and computational cost. To address these challenges, we propose a holistic co-design framework that incorporates a broader range of design values, integrates real-world prototyping to refine evaluations, and boosts efficiency through surrogate metrics and model-based control strategies. Finally, we outline research priorities in design priors and metrics, AI-assisted evaluation, and balancing computational refinement with physical testing and safety with performance.

The intelligent behavior of robots does not emerge solely from control systems, but from the tight coupling between body and brain, a principle known as embodied intelligence. Designing soft robots that leverage this interaction remains a significant challenge, particularly when morphology and control require simultaneous optimization. A significant obstacle in this co-design process is that morphological evolution can disrupt learned control strategies, making it difficult to reuse or adapt existing knowledge. We address this by develop a Graph Neural Network-based approach for the co-design of morphology and controller. Each robot is represented as a graph, with a graph attention network (GAT) encoding node features and a pooled representation passed through a multilayer perceptron (MLP) head to produce actuator commands or value estimates. During evolution, inheritance follows a topology-consistent mapping: shared GAT layers are reused, MLP hidden layers are transferred intact, matched actuator outputs are copied, and unmatched ones are randomly initialized and fine-tuned. This morphology-aware policy class lets the controller adapt when the body mutates. On the benchmark, our GAT-based approach achieves higher final fitness and stronger adaptability to morphological variations compared to traditional MLP-only co-design methods. These results indicate that graph-structured policies provide a more effective interface between evolving morphologies and control for embodied intelligence.