Component Influence-Driven Fastener Reduction for Robotic Disassemblability-Aware Design Simplification

Assembly Sequence Planning (ASP) remains a challenging problem due to its combinatorial nature, making exhaustive planning approaches impractical for complex industrial assemblies. Furthermore, many CAD models lack reliable semantic contact information or require extensive manual preprocessing, limiting the applicability of existing methods. This paper presents a hybrid ASP framework combining learning-based relation extraction with geometric-symbolic reasoning to generate feasible robotic disassembly sequences from imperfect CAD data. A neural network predicts semantic geometric relations from point clouds, while human-in-the-loop verification enables correction of uncertain predictions and planning failures. Extracted relations are transformed into a symbolic assembly graph, enabling a geometric-symbolic planner to efficiently compute locally valid sets of robotic manipulation primitives. A visibility-based ray-casting strategy guides the search for feasible disassembly directions without requiring an exhaustive combinatorial search, while the local solution space enables efficient sequence optimization. The framework is evaluated on an introduced assembly dataset and on the ASAP test dataset. On the ASAP test dataset, the proposed planner achieves an 85.83% planning success rate while reducing the median planning time by more than one order of magnitude across all assembly sizes and by more than a factor of 50 for assemblies with more than 30 components compared to the baseline. The results demonstrate that the proposed hybrid framework enables efficient robotic assembly sequence planning from imperfect CAD data while substantially reducing planning time. By combining learning-based feature segmentation, human-in-the-loop verification, and geometric-symbolic reasoning, the framework provides a practical foundation for scalable and adaptable robotic assembly and disassembly planning.

Open-source social robots offer accessibility, repairability, and student empowerment, yet the build itself often presents a barrier. Existing platforms either ship pre-assembled, foreclosing hands-on learning, or expose students to unfamiliar fasteners, opaque wiring, and inaccessible service points that erode engagement. Whether targeted mechanical redesign can lower this barrier whilst maintaining structural integrity remains untested. Here we show that Design for Assembly (DfA) and Design for Disassembly (DfD) interventions reshape how a build feels before they shorten how long it takes. Working with university students in Guyana and Estonia, we applied the Double Diamond framework to co-create the Robot Study Companion (RSC) v4.1: mapping pain points, then redesigning its chassis around twist-lock fasteners, snap-fit joints, and tool-free service latches. Across two studies with developers and first-time builders, system usability climbed from Poor to Excellent (SUS 59.4 to 89.4), perceived workload trended downward (NASA-TLX 4.29 to 4.00), and mean assembly time trended downward (21.4 to 13.7 minutes, with juniors' learning effect), whilst orientation cues and navigation continuity for first-time builders emerged as the next documentation frontier. Perceived workload, not completion time, appears to govern whether students take up open hardware.

Long-horizon multi-part object disassembly requires robots to compute feasible sequences of collision-free removal motions, even in the presence of tight, narrow escape corridors. To efficiently solve such disassembly problems, we propose Parallel Extraction for Long-Horizon Disassembly (PEEL), an algorithm which efficiently computes disassembly motions for object assemblies and feeds them to a robot manipulator for execution. PEEL uses sampling-based motion planning to compute single-object motions through the use of a scale-invariant sampling scheme, where the object scale is estimated in a burn-in phase and a subsequent directional sampler exploits the scale. This sampling scheme is integrated into a multi-arm bandit rapidly-exploring random tree (MAB-RRT) planner, which switches between different samplers depending on the reward signal received. Using MAB-RRT, the PEEL algorithm runs a batch of planners in parallel to obtain an ordered graph specifying the sequence in which object parts have to be removed. We show that MAB-RRT can efficiently solve single-part disassemblies with 100 percent success rate on 76 assemblies, and that it is robust to its parameters. By integrating MAB-RRT into PEEL, we solve four long-horizon disassembly problems using the Fetch manipulator robot involving 10 to 17 individual object parts.