Inverse Design of Metainterfaces for Static Friction Control: Beyond the Hertzian Limit

Existing approaches to frictional contact dynamics typically either modify the Coulomb law to improve numerical robustness or solve the exact law in a fully coupled monolithic form. However, in its reduced form, exact Coulomb friction can be written as a cone complementarity problem with an augmented velocity, which reveals a natural split between a cone-constrained linear response and a scalar non-associated coupling induced by tangential velocity. We exploit this structure in the solver design. Our method uses an outer iteration to update the non-associated coupling explicitly, and an inner solve for a strongly convex cone-constrained quadratic program. This separation also makes the inner solver modular, so different numerical schemes can be used without changing the outer iteration. We evaluate the method on rigid-body benchmarks with stick-slip transitions and frictional stacking, and show that it reproduces exact Coulomb complementarity without smoothing or relaxing the friction law.

Accurately estimating friction coefficients between arbitrary material pairs is critical for robotics, digital fabrication, and physics-based simulation, but exhaustive pairwise testing scales quadratically with the number of materials. We introduce a proxy-based modeling framework that approximates any pairwise friction $f(A,B)$ from a small, fixed set of proxy materials $C=[c_1,\dots,c_k]$ by learning a per-material embedding $z_A = g(f(A,c1),\dots,f(A,ck))$ and a fusion function $p$ such that $f(A,B)\approx p\big(z_A,z_B\big)$. We present deterministic and probabilistic realizations of $g$ and $p$, procedures for selecting diverse proxy sets, and mechanisms for handling missing or noisy proxy measurements. The learned embeddings are compact, interpretable, and enable calibrated uncertainty estimates for downstream decision making. On simulated and measured friction datasets, our approach achieves high predictive accuracy, robust performance with partial observations, and substantial experimental savings by significantly reducing pairwise testing.

Three properties determine whether a differentiable simulator can drive gradient-based optimization through contact: simulation accuracy, gradient reliability, and per-iteration cost. Tape-based engines such as MJX and Newton Semi-Implicit require timesteps small enough to keep contacts numerically tractable, and their backpropagation memory grows linearly with the number of timesteps T. Surrogate models bound memory by approximating contact away, but the resulting gradients lose the geometry the optimization depends on. We present Ostrich, a GPU-accelerated rigid-body simulator that resolves hard contacts and friction with non-smooth Newton iteration at large timesteps (h ~ 0.1 s), and differentiates the converged residual via the implicit function theorem, reusing the forward Schur complement to compute the adjoint at O(1) memory per timestep. On real-robot trajectories over a pallet obstacle, Ostrich holds MuJoCo's sim-to-real accuracy up to a 50x larger timestep. Its gradients converge from random initializations where MJX descends slowly and Newton Semi-Implicit stalls; a warm iteration runs 211x faster than MJX's and 4.7x faster than Semi-Implicit's. On the same scene Ostrich differentiates 8,192 parallel worlds on a single 24 GB GPU, sustaining 29x checkpointed MJX's optimization throughput; without checkpointing both baselines exhaust memory at far fewer worlds. We close with a gradient-based trajectory optimization demonstration over triangle-mesh terrain across a 10 s horizon, a setting where prior engines either restrict to primitive geometry or face the convergence and memory limits shown above.