Diffusion policies have achieved remarkable success in robotic manipulation, yet they often fail to satisfy strict physical constraints required for safe deployment. Existing approaches impose safety either prematurely during training or reactively via external guardrails at test time, limiting policy expressivity and overall scalability. We propose Physical safety Alignment for Constrained Trajectories (PACT), a self-evolving post-training framework that projects pretrained diffusion policies onto constraint-feasible regions without accessing demonstration data or task rewards. PACT distills constraint gradients into the diffusion model through a reverse-KL objective with dense supervision across timesteps. It incorporates a curriculum that progressively tightens constraints while maintaining theoretically bounded policy shift and monotone improvement, mitigating the safety-performance trade-off from catastrophic forgetting. On simulated and real-world embodied manipulation benchmarks, PACT significantly reduces safety violations by 31.0% on average while improving task success by 30.7%.
Vision-Language-Action (VLA) and World-Action Models (WAMs) have demonstrated strong capabilities in general-purpose robotic manipulation, yet their generated actions may violate hard physical constraints and therefore be unsafe or infeasible for deployment. Existing safety approaches either optimize statistical safety objectives without deterministic per-step guarantees or correct unsafe actions only during inference, creating a mismatch between policy training and execution. We introduce ActSafeGuard, a differentiable and training-aligned safeguard layer for flow-matching based policies. ActSafeGuard integrates hard action feasibility into policy learning, not merely treating safety as an inference-time external component. Through an analytical ray-scaling operator design, ActSafeGuard enables boundary-aware gradients to guide the model to naturally learn constrained manifolds. Extensive experiments on multiple standard foundation backbones (π0.5 and Fast-WAM) across various tasks demonstrate that ActSafeGuard consistently achieves a 100% step safety rate while fully preserving or even boosting task success rates, providing a scalable and minimally invasive solution for safe embodied AI deployment.
Diffusion models sample effectively from high-dimensional, multimodal distributions, but their outputs may violate deployment constraints. For task-space robot policies, generated grasps, waypoints, or trajectories can be distributionally valid yet infeasible, violating reachability, collision-avoidance, or closed-loop executability requirements. This embodiment gap limits zero-shot deployment across robots, even when the task-space behavior itself is transferable. We propose an inference-time optimization framework that couples the behavior generation to physical feasibility by formulating diffusion guidance as a constrained optimization problem. Our key insight is to replace the sampling perturbation in the backward process with an optimized correction, allowing hard constraints or soft penalties to be imposed during sampling without the need to retrain the diffusion model, while keeping samples close to the learned prior. We evaluate the method on dexterous grasp synthesis with reachability and collision-avoidance constraints, and dynamic manipulation with controller-level trackability constraints. Across settings and robot embodiments, optimization-guided denoising matches the feasibility of projection- and gradient-guidance baselines while better preserving grasp quality, and improving controller-level executability and task success, with task success improving by up to 20pp. on dexterous grasping and 23pp. on visuomotor manipulation over the best baseline.
Reinforcement learning (RL) has emerged as a promising solution to accomplish complex robotic control tasks; however, most of the current work ignores the safety requirements. Safe RL seeks to maximize task performance while satisfying explicit physical constraints, but current algorithms struggle to learn the policy efficiently with precise constraint satisfaction. This work proposes PPO-EAL, a novel first-order constrained policy optimization framework that integrates exact augmented Lagrangian optimization into proximal policy optimization for safe robotic control. By combining clipped policy updates with exact quadratic penalty terms, PPO-EAL achieves theoretically grounded constraint enforcement without requiring impractically large penalty factors. A momentum-regulated multiplier update further improves dual-variable stability, reducing constraint oscillation and unsafe behavior while preserving task performance. We provide exactness and convergence analysis under standard stochastic approximation assumptions. Extensive validation across diverse GPU-accelerated robotic benchmarks-including cart-pole balancing, cart-double-pendulum stabilization, 7-DoF Franka end-effector reaching, and quadrupedal locomotion-demonstrates superior safety precision and reward performance compared with state-of-the-art first-order safe RL baselines. Finally, we demonstrate zero-shot sim-to-real deployment in a contact-rich gear assembly task, where PPO-EAL substantially improves task success, reduces peak contact force, and enhances operational robustness. These results establish PPO-EAL as a general and practically deployable safe RL framework for diverse safety-critical robotic systems.