FLASH: Fast Learning via GPU-Accelerated Simulation for High-Fidelity Deformable Manipulation in Minutes
Authors: Siyuan Luo, Bingyang Zhou, Chong Zhang, Xin Liu, Zhenhao Huang, Gang Yang, Zhengtao Han, Xiaotian Hu, +4 more
Organizations: NUS Human-Centered Robotic Lab · ETH · ShanghaiTech University · Independent Researcher · Gradient
Abstract
Simulation frameworks such as Isaac Sim have enabled scalable robot learning for locomotion and rigid-body manipulation; however, contact-rich simulation remains a major bottleneck for deformable object manipulation. The continuously changing geometry of soft materials, together with large numbers of vertices and contact constraints, makes it difficult to achieve high accuracy, speed, and stability required for large-scale interactive learning. We present FLASH, a GPU-native simulation framework for contact-rich deformable manipulation, built on an accurate NCP-based solver that enforces strict contact and deformation constraints while being explicitly designed for fine-grained GPU parallelism. Rather than porting conventional single-instruction-multiple-data (SIMD) solvers to GPUs, FLASH redesigns the physics engine from the ground up to leverage modern GPU architectures, including optimized collision handling and memory layouts. As a result, FLASH scales to over 3 million degrees of freedom at 30 FPS on a single RTX 5090, while accurately simulating physical interactions. Policies trained solely on FLASH-generated synthetic data in minutes achieve robust zero-shot sim-to-real transfer, which we validate on physical robots performing challenging deformable manipulation tasks such as towel folding and garment folding, without any real-world demonstration, providing a practical alternative to labor-intensive real-world data collection.
RGB sim-to-real for deformable manipulation has remained largely unsolved without real-world fine-tuning. We present SimWeaver, which trains zero-shot RGB VLA policies on 200 simulated demonstrations per task, reaching above 80% per-task and 91% average real-world success across 5 diverse deformable tasks including plastic-bag manipulation, without teleoperation or per-task calibration. SimWeaver combines a reliable measurement-backed simulator (SimWeaver-Sim) with an extensible asset framework supporting single-image generation(SimWeaver-Asset), a deterministic topology-aware trajectory synthesizer (SimWeaver-Syn), and a sim-to-real protocol with ISP-aware photometric augmentation (SimWeaver-Real). On silk grasping, the sim-trained policy reaches 100% under visual distribution shifts where real-data baselines drop to 9-70%, at two orders of magnitude lower per-trajectory cost. We will release SimWeaver and a representative asset subset. Project page: https://simweaver.github.io/
Simulator-in-the-loop optimization offers a promising inference-time mechanism for robot manipulation. It uses a physical simulator as a backend rollout engine to evaluate candidate trajectories in parallel and refine nominal actions online, a paradigm proven effective in rigid-body manipulation where state and contact are relatively tractable. We bring this paradigm to real-world cloth manipulation from a single RGB input through three pillars. (i) We design a scalable synthetic-data generation and inference-time rollout pipeline built on FLASH, a deformable-object simulator that provides a practical balance among physical fidelity, numerical stability, and rollout efficiency. (ii) We develop a real-to-sim module, trained purely on synthetic data, that maps a single RGB observation to simulation-compatible cloth state by fusing pretrained visual features with learnable canonical tokens. (iii) We perform online planning by coupling a sparse-mesh rollout backend with prior-guided MPPI, anchored at an offline-distilled policy trajectory, preserving manipulation-relevant deformation and contact while enabling sufficient parallel rollout batches. Real-robot experiments show higher success rates and stronger robustness than baseline methods.
Simulating deformable objects is essential for a wide range of robotic manipulation applications, yet accurately predicting their dynamics remains challenging. We propose Physics-Guided Residual Dynamics (PGRD), a hybrid simulation framework that combines the advantages of physics-based and learning-based approaches. Specifically, PGRD combines an optimizable spring-mass simulator as a backbone with a learned neural network that predicts residual corrections to the physics-based predictions. We adopt a velocity-based formulation to ensure stable simulation and a sliding-window transformer architecture to capture temporal dependencies. We show that PGRD produces more accurate results than both purely physics-based and learning-based methods on a set of diverse real-world deformable objects. We further demonstrate the utility of PGRD in two applications: manipulation planning via Model Predictive Control, including a language-conditioned setting with a generated goal image; and interactive simulation via action-conditioned video prediction by 3D Gaussian Splatting.