DLO-Lab: Benchmarking Deformable Linear Object Manipulations with Differentiable Physics

Deformable Linear Objects (DLOs), such as wires and cables, are central to industrial assembly. Unlike rigid objects, whose state is captured by a 6-DoF pose, DLOs have an infinite-dimensional configuration space and deform continuously under contact with grippers, fixtures, and the workspace, making them a demanding benchmark for general dexterous manipulation. Despite their importance, policy development and comparison remain difficult: existing benchmarks are often tied to specific hardware setups, lack modular and customizable task assets, or study generic deformable-object tasks without the fixtures relevant to real-world industrial wire manipulation. Few benchmarks align simulation, real-world data, and shared evaluation protocols. To bridge this gap, we introduce WireCraft, a simulation benchmark for industrial DLO manipulation with configurable difficulty and assets, spanning three task families: connector insertion, clip routing, and channel seating. It supports two complementary DLO physics models, articulated and deformable, and the trajectories come from both simulation and a physical UR5. We benchmark reinforcement learning (RL), imitation learning (IL), and vision-language-action (VLA) policies under shared metrics. Privileged state-based RL solves a representative setting in each task family with over 82% success, confirming the tasks are well-posed. For connector insertion, however, the transition from reaching the socket to contact-rich alignment remains a key bottleneck for vision RL, IL, and VLA policies. These results indicate that industrial DLO manipulation, though tractable under privileged state, remains an open challenge for current vision-based learning. The benchmark, data, and tools will be open-sourced upon acceptance.

Deformable linear objects (DLOs) such as wires, cables, and ropes are common in robotic manipulation tasks, yet simulating them with both visual realism and physical accuracy remains challenging. Existing visual simulation methods typically rely on procedural geometric primitives that lack physically grounded deformation behavior, while physics-based approaches with robot learning support often approximate DLOs as rigid-link chains or generic soft bodies, failing to accurately capture the bending, twisting, and shear mechanics of slender elastic structures. In this work, we introduce DeformX, a co-simulation framework that integrates a dedicated Cosserat rod physics engine with NVIDIA Isaac Sim, enabling DLO simulations that are both physically faithful and visually realistic. Our Cosserat rod engine simulates the dynamics and self-collisions of DLOs, and contact interactions with arbitrary free-form meshes. To achieve high-fidelity visualization, we employ mesh skinning to map discrete rod deformations onto imported CAD models. To the best of our knowledge, DeformX is the one of the first frameworks for DLO simulation that unifies realistic visualization, principled physics, and compatibility with robot learning pipelines. We demonstrate its versatility across synthetic data generation and policy learning for DLO manipulation, and validate visual and physical fidelity through comparisons against real-world experiments. Notably, fine-tuning Segment Anything Model 3 (SAM3) on DeformX-generated data yields a 10.2% mAP@75 improvement in real-image wire segmentation, and a rope-swinging policy trained entirely in DeformX achieves a mean target-hitting error of 6.6 cm on a UR5e manipulator in real-world trials, highlighting its strong sim-to-real transfer capability.

Deformable Linear Objects (DLOs) such as ropes and cables are widely encountered in both household and industrial applications, yet remain challenging to manipulate due to their infinite-dimensional configuration space and frequent self-occlusion. Imitation learning from teleoperation offers a practical path to bimanual DLO manipulation, but its scalability is limited by human effort, making the choice of observation space critical for generalization from small datasets. In this study, we investigate whether the lack of generalization in egocentric visual policies for the knot-untangling task stems from the observation space itself, rather than from the policy architecture or data scale. We compare two Action Chunking with Transformers policies trained on the same bimanual teleoperation data: a vision-based policy conditioned on two egocentric RGB streams from wrist-mounted cameras, and a state-based policy conditioned on the DLO's 3D particle state, extracted from an initial observation via multi-view fusion and evolved in a particle-based eXtended Position-Based Dynamics simulation. Evaluated open-loop on an unseen rope configuration, the state-based policy outperforms its visual counterpart with a 30.8% reduction in L1 error when predicting the initial grasp-and-pull action, quantifying the observability gap between pixels and physics-consistent state, and pointing toward more data-efficient robot learning for the DLO manipulation task from limited human demonstrations.