Rapid co-design of Buoyancy-assisted robots for Challenging Locomotion using Gaussian Evolutionary Specialists
Authors: Ankit Sinha, Nitish Sontakke, Dennis Hong, Yusuke Tanaka, Sehoon Ha
Abstract
Designing high-performance legged robots requires jointly optimizing morphology and control. Model-free Reinforcement Learning (RL) offers an alternative to model-predictive control for developing robust controllers without explicitly specifying robot dynamics. Thus, we have seen theuse of RL to train controllers and evaluate designs for robot morphology optimization. While RL has shown success inlocomotion, using it in the co-design inner loop is expensive due to repeated policy training. Universal policies conditioned on morphology offer a promising alternative, but suffer from behavioral diversity collapse, converging to a single strategy that performs sub-optimally across designs. On the other hand, end-to-end Mixture-of-Experts (MoE) architectures fail due to a collapse in its representation. We propose Gaussian Evolutionary Specialists (GES), a framework that decouples design-space partitioning from policy learning to capture diverse behaviors explicitly. GES assigns specialist policies to evolving Gaussian regions and iteratively refines them via training, probing, and territory expansion. The resulting specialists are integrated into a design sampling loop, replacing costly re-training with direct evaluation. When tested on the Buoyancy-Assisted Light Legged Unit (BALLU), GES discovers designs with 5 - 25% higher performance than naive universal policies. On hardware, a GES optimized design overcomes a 24 cm tall obstacle - 3x improvement over the baseline BALLU design. Moreover, GES curtails design optimization time by 37%.
In this paper, we introduce a model of evolution and learning in robots that co-optimizes a distribution of latent design vectors (genotypes) and a mixture of control experts (neural modules), which are gated by the latent coordinates of each decoded design (phenotype). This provides a scalable alternative to co-design algorithms that either train an individual policy for every robot, which is inefficient, or a monolithic universal controller for all robots, which results in overly conservative structures and behaviors. Our approach lies somewhere between these two extremes, preserving ancestral knowledge in a unified yet modular framework in which different body plans activate and deactivate different combinations of learned sensorimotor circuits for goal-directed behavior. This allows one part of the controller to be overhauled to better suit new species of designs as they emerge without disrupting the hard-earned knowledge contained within other expert modules. It also allows pretrained expert policies to be directly plugged into the mixture, which can steer evolution into otherwise unexplored areas of latent space containing desired morphological traits. We refer to this process as "evo by demo" and explore how it may be used to guide freeform evolution toward canonical structures defined by the pretrained model. Videos and code can be found at: https://eco-moe.github.io.
Co-design of legged robots with elastic elements is challenging due to the non-differentiability of contact dynamics and mechanism engagement. This paper presents SurGE, a framework that computes surrogate gradients of the design objective through a differentiable pipeline consisting of a kinodynamic single-rigid-body (Kino-SRB) model and a design-aware control policy, and injects them into CMA-ES via mean shift with cosine-annealed step decay. On a 4-DOF design space of a hopping robot with unidirectional parallel spring, SurGE achieves 6 times lower cross-seed standard deviation and 18% tighter population concentration compared to vanilla CMA-ES, while matching or improving the best objective. Hardware experiments on a 2D design subspace show that, starting from a hand-tuned initial design, SurGE reduces the design objective by 37.65% on hardware, with the improvement trend identified in simulation transferring consistently to the physical system. SurGE provides the potential to accelerate non-differentiable co-design problems in legged robots via surrogate model gradients.
Large language models (LLMs) are increasingly used as proposal generators for evolutionary robot design, yet most loops remain memoryless: simulator results shape the next population but are not preserved as reusable design knowledge. We present Auto-Robotist, a self-evolving LLM agent that distills morphology-search traces into an explicit natural-language skill library. Each skill stores a structural archetype, evidence-grounded positive and negative rules, and the evaluated designs that support them, making design memory inspectable rather than implicit in a population. During search, the agent retrieves skills to condition LLM edits of elite bodies while retaining a Genetic Algorithm (GA) mutation path for exploration; after evaluation, it updates the library through Add, Diagnose, and Merge. Across seven EvoGym tasks spanning locomotion, traversal, and object interaction, Auto-Robotist improves cold-start 5x5 search and transfers learned skills to 10x10 design spaces, where reference-conditioned transfer outperforms GA on every task. These results suggest that LLM agents can convert expensive physical evaluations into reusable, auditable design principles. Our code will be released upon acceptance.