Zero-Shot Sim-to-Real Robot Learning: A Dexterous Manipulation Study on Reactive Catching
Authors: Kejia Ren, Gaotian Wang, Andrew S. Morgan, Kaiyu Hang
Organizations: Department of Computer Science, Rice University · Robotics and AI Institute
Abstract
Dexterous manipulation is physics-intensive and highly sensitive to modeling errors and perception noise, making sim-to-real transfer prohibitively challenging. Domain randomization (DR) is commonly used to improve the robustness of learned policies for such tasks, but conventional DR randomizes one instance per episode, offering very limited exposure to the variability of real-world dynamics. To this end, we propose Domain-Randomized Instance Set (DRIS), which represents and propagates a set of randomized instances simultaneously, providing richer approximation of uncertain dynamics and enabling policies to learn actions that account for multiple possible outcomes. Supported by theoretical analysis, we show that DRIS yields more robust policies and alleviates the need for real-world fine-tuning, even with a modest number of instances (e.g., 10). We demonstrate this on a challenging reactive catching task. Unlike traditional catching setups that use end-effectors designed to mechanically stabilize the object (e.g., curved or enclosing surfaces), our system uses a flat plate that offers no passive stabilization, making the task highly sensitive to noise and requiring rapid reactive motions. The learned policies exhibit strong robustness to uncertainties and achieve reliable zero-shot sim-to-real transfer.
Sim-to-real transfer remains a critical bottleneck for deploying dexterous manipulation policies learned in simulation to real-world robots. Existing approaches rely on manually designed domain randomization or task-specific adaptation, limiting their generalizability across diverse manipulation scenarios. We present DexSim2Real, an integrated framework that leverages vision-language foundation models to bridge the sim-to-real gap for dexterous manipulation. Our system combines three components: (1) Foundation Model-Guided Domain Randomization (FM-DR), which uses a vision-language model as a visual realism critic to optimize simulation parameters via closed-loop CMA-ES, complementing text-based approaches like DrEureka with direct visual feedback; (2) a Tactile-Visual Cross-Attention Policy (TVCAP) that adapts cross-attention visuo-tactile fusion to zero-shot sim-to-real RL; and (3) a Progressive Skill Curriculum (PSC) that builds on LLM-based task decomposition with a difficulty scheduler tailored to contact-rich dexterous tasks. Extensive experiments on six challenging manipulation tasks with blinded evaluation demonstrate that DexSim2Real achieves a 78.2% average real-world success rate, outperforming DrEureka and DeXtreme while reducing the sim-to-real performance gap to only 8.3%.
Sim-to-real transfer in robot learning is often limited by discrepancies between the ideal actuator dynamics assumed during policy training and the nonlinear, hardware-dependent behavior of physical motors. While conventional approaches attempt to bridge this gap by increasing simulator fidelity through system identification, domain randomization, or learned actuator models, we introduce an alternative paradigm: actuator reality shaping. Instead of modifying the simulator to match the real world, our method shapes the closed-loop behavior of physical actuators to match the idealized second-order reference dynamics used in simulation. By equipping each joint with a two-degree-of-freedom feedforward--feedback controller, we decouple reference-response shaping from robust stabilization, thereby providing a standardized actuator interface for reinforcement learning policies. As a result, policies trained only with the prescribed reference model can be deployed zero-shot on real hardware without task-level fine-tuning or learned actuator models. We validate the approach on a single-joint high-gear-ratio servo under external loads and a 7-DOF robotic arm reaching task, where actuator reality shaping substantially reduces sim-to-real tracking error and improves zero-shot task performance compared with standard servo-control and representative real-to-sim-to-real baselines. We further demonstrate zero-shot transfer on a wheeled-legged robot driving over a slope and a humanoid robot walking, suggesting that actuator reality shaping can serve as a reusable interface for robot learning across diverse hardware platforms. Project page: https://syamamori.github.io/ActuatorRealityShaping.github.io/
Satoshi Yamamori, Koji Ishihara, Kenjiro Minamikawa +4
Bridging the sim-to-real gap is a core challenge in deploying learned manipulation policies. Sim-to-real learning is attractive because it can replace expensive real robot demonstrations with scalable synthetic data, yet world-action models have not previously been shown to transfer from simulation to real robotic manipulation. We study whether a world-action model can be trained from synthetic priors and deployed zero-shot in the real world. To this end, we build upon Cosmos Policy, a video diffusion model adapted for visuomotor control. We construct simulation environments with extensive domain randomization and generate demonstrations using the AnyTask motion planning pipeline. We evaluate our approach across object lifting, drawer opening, and pick-and-place tasks using ∼800 synthetic demonstrations per task and no real demonstrations. When deployed zero-shot on a Franka Robot, our policy attains a 35% average success rate. To our knowledge, this represents the first successful sim-to-real transfer of a world-action model for robotic manipulation.