Closed-Loop Sim-to-Real Reinforcement Learning for Deformable Microfiber Shape Control

Human-like dexterous hands with multiple fingers offer human-level manipulation capabilities but remain difficult to train the control policies that can deploy on real hardware due to contact-rich physics and imperfect actuation. We present a sim-to-real reinforcement learning method that leverages dense tactile feedback combined with joint torque sensing to explicitly regulate physical interactions. To enable effective sim-to-real transfer, we introduce (i) a computationally fast tactile simulation that computes distances between dense virtual tactile units and the object via parallel forward kinematics, providing high-rate, high-resolution touch signals needed by RL; (ii) a current-to-torque calibration that eliminates the need for torque sensors on dexterous hands by mapping motor current to joint torque; and (iii) actuator dynamics modeling with randomization to account for non-ideal torque-speed effects and bridge the actuation gaps. Using an asymmetric actor-critic PPO pipeline, we train policies entirely in simulation and deploy them directly to a five-finger hand. The resulting policies demonstrate two essential human-hand skills: (1) command-based controllable grasp force tracking and (2) reorientation of objects in the hand, both of which are robustly executed without fine-tuning on the robot. By combining tactile and torque in the observation space with scalable sensing and actuation modeling, our system provides a practical solution to achieve reliable dexterous manipulation. To our knowledge, this is the first demonstration of controllable grasping on a multi-finger dexterous hand trained entirely in simulation and transferred zero-shot on real hardware.

A key challenge in contact-rich dexterous manipulation is the need to jointly reason over global geometry and nonsmooth contact dynamics. End-to-end policies bypass this complexity, but often require large amounts of data and transfer poorly from simulation to reality. We address the limitations with a simple insight: dexterous manipulation is inherently hierarchical--at a high level, a robot decides where to touch (geometry); at a low level it determines how to move the object through contact dynamics. Building on this insight, we propose a hierarchical RL--MPC framework in which a high-level reinforcement learning (RL) policy predicts a contact intention, a novel object-centric interface that specifies (i) an object-surface contact location and (ii) a post-contact object subgoal pose. Conditioned on the contact intention, a low-level contact-implicit model predictive control (MPC) optimizes local contact modes and real-time (re)plans through contact dynamics to generate robot actions that robustly move the object toward each subgoal. We evaluate the framework on non-prehensile tasks, including geometry-generalized pushing across diverse object shapes, pivoting/flipping-based object reorientation, and environment-assisted object repositioning. It achieves high success rate with substantially reduced data (10 times less than end-to-end baselines), highly robust performance, and zero-shot sim-to-real transfer.

Real-world reinforcement learning (RL) offers a promising route to dexterous manipulation policies that can adapt directly from physical interaction, but learning is hindered by inefficient early exploration and costly failures. We propose a framework that uses sampling-based model predictive control (MPC) as scaffolding for real-world dexterous RL, providing structured prior experience and task-directed guidance during learning without human demonstrations or corrective actions. A small set of MPC trajectories is first used to populate an offline replay buffer and to pretrain the actor and critic. During online learning, MPC intermittently guides data collection while an off-policy Soft Actor-Critic learner trains from both prior MPC experience and newly collected physical interaction, with control gradually transitioning to the learned policy. On continuous in-hand rotation with a 16-DoF Allegro hand, initialized from 20 MPC trajectories collected in 12 minutes on hardware, the policy reaches 100% success after 7 minutes of online RL, with about three object drops on average during training. After 20 minutes of online learning, the policy achieves more than five times the rotation speed of the MPC controller and completes 1000 consecutive rotations without a drop. Ablations show complementary benefits from MPC-based pretraining, retained MPC experience, and online MPC guidance, while additional experiments demonstrate rapid adaptation to new object geometries and successful goal-conditioned reorientation.