TaCauchy: An Extensible FEM Framework for Vision-Based Tactile Simulation
Authors: Hengfei Zhao, Yifan Xie, Junhao Gong, Yue Sun, Kai Zhu, Weihua He, Shoujie Li, Haohuan Fu, +1 more
Abstract
Vision-based tactile sensors require high-fidelity simulation for reinforcement learning, yet existing approaches struggle to provide accurate mechanical stress fields within GPU-accelerated robotics platforms. We present TaCauchy, an extensible Finite Element Method (FEM) framework that integrates rigorous physics-based force computation into Isaac Sim. Built on the Unified Incremental Potential Contact (UIPC) solver, TaCauchy directly computes Cauchy stress tensors from hyperelastic constitutive laws and projects them onto contact surfaces to obtain traction forces and pressure distributions, providing mechanical ground truth from first principles rather than empirical estimation. Our framework features automatic mesh generation with geometry-aware adaptive refinement and a modular sensor interface enabling rapid integration of diverse sensors (GelSight Mini, DIGIT, 9DTact) with minimal configuration. Performance benchmarks demonstrate 33.40 FPS for single environments and 555 FPS aggregate throughput across 60 parallel environments, with stress extraction overhead under 1 ms. Physical validation experiments show strong agreement between simulated and real tactile responses across force ranges from 1.2556 N to 4.7332 N, achieving SSIM above 0.93, confirming the framework's capability to provide accurate, physically-grounded force supervision for downstream robotic manipulation tasks.
Tactile sensors are increasingly integrated into dexterous robotic manipulators to enhance contact perception. However, learning manipulation policies that rely on tactile sensing remains challenging, primarily due to the trade-off between fidelity and computational cost of soft-body simulations. To address this, we present ETac, a tactile simulation framework that models elastomeric soft-body interactions with both high fidelity and efficiency. ETac employs a lightweight data-driven deformation propagation model to capture soft-body contact dynamics, achieving high simulation quality and boosting efficiency that enables large-scale policy training. When serving as the simulation backend, ETac produces surface deformation estimates comparable to FEM and demonstrates applicability for modeling real tactile sensors. Then, we showcase its capability in training a blind grasping policy that leverages large-area tactile feedback to manipulate diverse objects. Running on a single RTX 4090 GPU, ETac supports reinforcement learning across 4,096 parallel environments, achieving a total throughput of 869 FPS. The resulting policy reaches an average success rate of 84.45% across four object types, underscoring ETac's potential to make tactile-based skill learning both efficient and scalable.
Vision-based tactile sensing is widely used in perception, reconstruction, and robotic manipulation, yet collecting large-scale tactile data remains costly due to diverse sensor-object interactions and inconsistencies across sensor instances. Existing approaches to scaling tactile data---simulation and free-form tactile generation---often yield unrealistically rendered signals with poor transfer to highly dynamic real-world tasks. We propose \name, a two-stage controllable tactile image generation framework that generates realistic tactile images conditioned on a single reference tactile image, contact force, and contact pose. By grounding generation in these important physical priors, \name synthesizes realistic samples across different sensors while effectively capturing task-relevant variations. Across a series of downstream tasks and real-world experiments, such as object insertion, imitation learning, and object weighting, the augmented datasets using our approach consistently improve performance and demonstrate practical utility in dynamic real-world settings. Project page: https://dongyuluo.github.io/controltac.
Tactile perception is key to dexterous manipulation, yet simulating high-resolution elastomer deformation remains computationally prohibitive. Finite element methods (FEM) deliver high fidelity but demand costly remeshing, while Material Point Methods (MPM) suffer from heavy particle-memory tradeoffs. We propose a {reduced-order neural simulation framework} that couples coarse-grained MPM dynamics with an implicit neural decoder to reconstruct sub-particle tactile details from compact latent states. The framework learns a continuous deformation manifold from paired high- and low-resolution simulations, enabling physically consistent, differentiable inference. Compared to the TacIPC, our method achieves over 65% faster simulation and {40% lower memory usage}, while maintaining better geometric fidelity. In tactile rendering and 3D surface reconstruction, our methods further improve accuracy by 25% and produce realistic depth images and surface mesh within a faster inference speed. These results demonstrate that the proposed reduced-order neural model enables high-detail, physically grounded tactile simulation with substantial efficiency gains for robotic interaction and optimization.