DOT-Sim: Differentiable Optical Tactile Simulation with Precise Real-to-Sim Physical Calibration
Authors: Yang You, Won Kyung Do, Aiden Swann, Rika Antonova, Monroe Kennedy, Leonidas Guibas
Organizations: Stanford University, United States · University of Cambridge, United Kingdom
Abstract
Simulating optical tactile sensors presents significant challenges due to their high deformability and intricate optical properties. To address these issues and enable a physically accurate simulation, we propose DOT-Sim: Differentiable Optical Tactile Simulation. Unlike prior simulators that rely on simplified models of deformable sensors, DOT-Sim accurately captures the physical behavior of soft sensors by modeling them as elastic materials using the Material Point Method (MPM). DOT-Sim enables rapid calibration of optical tactile sensor simulation using a small number of demonstrations within minutes, which is substantially faster than existing methods. Compared to current baselines, our approach supports much larger and non-linear deformations. To handle the optical aspect, we propose a novel approach to simulating optical responses by learning a residual image relative to the real-world idle state. We validate the physical and visual realism of our method through a series of zero-shot sim-to-real tasks. Our experiments show that DOT-Sim (1) accurately replicates the physical dynamics of a DenseTact optical tactile sensor in reality, (2) generates realistic optical outputs in contact-rich scenarios, (3) enables direct deployment of simulation-trained classifiers in the real world, achieving 85% classification accuracy on challenging objects and 90% accuracy in embedded tumor-type detection, and (4) allows precise trajectory following with a policy trained from demonstrations in simulation, with an average error of less than 0.9 mm.
Training machine learning models for robotic tactile sensing requires vast amounts of data, yet obtaining realistic interaction data remains a challenge due to physical complexity and variability. Simulating tactile sensors is thus a crucial step in accelerating progress. This paper presents SPLIT, a novel method for simulating image-based tactile sensors, with a primary focus on the DIGIT sensor. Central to our approach is a latent space arithmetic strategy that explicitly disentangles contact geometry from sensor-specific optical properties. Unlike methods that require recalibration for every new unit, this disentanglement allows SPLIT to adapt to diverse DIGIT backgrounds and even transfer data to distinct sensors like the GelSight R1.5 without full model retraining. Beyond this adaptability, our approach achieves faster inference speeds than existing alternatives. Furthermore, we provide a calibrated finite element method (FEM) soft-body mesh simulation with variable resolution, offering a tunable trade-off between speed and fidelity. Additionally, our algorithm supports bidirectional simulation, allowing for both the generation of realistic images from deformation meshes and the reconstruction of meshes from tactile images. This versatility makes SPLIT a valuable tool for accelerating progress in robotic tactile sensing research.
Tactile sensing provides direct measurements of contact interactions that are essential for robotic manipulation. However, current simulators lack the fidelity to faithfully model the complex deformation and transduction mechanics of tactile sensors, severely hindering sim-to-real transfer in robot learning pipelines. To address this challenge, we propose a multi-modal representation learning framework that aligns heterogeneous tactile modalities within a shared latent space, eliminating the need for accurate raw-signal simulation while preserving relevant contact information. Our approach employs modality-specific encoders to project diverse tactile observations, such as simulated penetration depth and real-world capacitance, into a common embedding space. The model is trained using self- and cross-reconstruction objectives alongside contrastive alignment, encouraging modality-invariant yet information-rich representations. We evaluate the learned embeddings on indenter shape identification, force prediction, and geometric reconstruction tasks, training exclusively in simulation and testing directly on real sensor measurements. Our results demonstrate zero-shot sim-to-real transfer across physically dissimilar representations. Furthermore, incorporating multi-physics simulation modalities yields more informative embeddings that transfer across diverse downstream tasks, demonstrating a 16.7% reduction in force prediction error and a 45.8% reduction in shape reconstruction error. Finally, we release an efficient Warp-based implementation of a penalty-based tactile simulation model for Isaac Lab, enabling scalable tactile data generation.
A primary bottleneck in contact-rich manipulation is the difficulty of collecting real-world data. Sim-to-real reinforcement learning offers a scalable alternative, but the simulation-reality gap prevents information-dense modalities like touch from being effectively used. Existing sim-to-real methods often mitigate this gap by simplifying tactile data into coarse low-dimensional features -- sacrificing the richness required for complex manipulation. In this work, we introduce Center-of-Pressure (CoP), an effective tactile representation grounded in physical principles that preserves dense contact information while maintaining robustness for sim-to-real transfer. To support this representation, we propose a sensor calibration scheme based on differentiable dynamics, enabling the estimation of taxel orientations without requiring ground-truth force measurements. We evaluate CoP on two blind, challenging contact-rich manipulation tasks: peg-in-hole insertion and ball balancing. Across both tasks, policies conditioned on CoP achieve zero-shot sim-to-real transfer on a multi-fingered hand, and outperform both coarse binary-contact and raw-taxel baselines. Analysis of learned policy states further suggests that CoP-conditioned policies encode task-relevant physical properties, such as object mass, as an emergent byproduct of control.