Real2Sim2Real for Vision-Language-Action Manipulation: An AMD ROCm-Based Pipeline

Real-to-sim conversion for robotic interaction with objects remains labor-intensive because it requires more than visual reconstruction: a streamlined real2sim process must recover scene geometries and object states, infer physical parameters, and assemble actors, objects, cameras, poses, and trajectories into a runnable physical simulation. Today this process still depends on brittle workflow glue across visual perception tools and simulators: manual tuning of visual foundation models, mesh cleanup, coordinate frame alignments, etc. We introduce \textit{Agentic Real2Sim}, a framework for generalized physical world modeling with vision-language agents that converts a real-world recording of object-robot interaction into a simulatable episodic twin, and connects the resulting twin to downstream policy fine-tuning and evaluation. We evaluate Agentic Real2Sim on rigid-object manipulation, deformable-object interaction, and humanoid motion scenes, spanning domains that are usually handled by separate Real2Sim pipelines. The framework's agentic decisions can be driven by an open-weight VLM backend at a small fraction of the cost of frontier models, while attaining a comparable conversion success rate. The framework further supports custom scene conversion, fine-tuning of a pretrained policy with data generated from converted episodes, and works effectively as a surrogate for real-world policy evaluation. The project site, including code is available at https://agentic-real2sim.github.io.

Vision-Language-Action (VLA) models can generalize across diverse manipulation tasks, but their imitation-learning-based policies remain brittle in precise physical interactions due to compounding execution errors; Can a reinforcement learning policy trained purely in simulation improve the robustness of real-world VLAs zero-shot? Residual RL, which learns a corrective policy on top of a frozen VLA, offers a natural framework, but existing approaches face a fundamental sim-to-real dilemma: privileged-state methods require lossy distillation for deployment; image-based methods suffer from the visual domain gap; and real-world RL is costly and unsafe. We propose an object-centric residual RL framework that refines VLA actions using object poses, enabling a compact observation space that transfers consistently between simulation and reality. To align the two domains, we additionally replay the same teleoperation demonstrations in simulation to train a sim counterpart of the real-world VLA. The residual RL policy is trained only in simulation with pose noise injection and dropout, and transfers zero-shot to the real robot. Across five manipulation tasks on a real Franka Research 3 (FR3) robot, our method improves the success rate from 42% to 76% zero-shot, and the improved rollouts can be further reused to retrain the base VLA for self-improvement without additional teleoperation. Project page: https://www.microsoft.com/en-us/research/articles/object-centric-residual-rl/

Vision-Language-Action (VLA) models excel at mapping visual inputs and natural language instructions directly to robotic control policies. However, because they are trained primarily to fit behavioural demonstration data, they do not explicitly enforce fundamental physical principles such as rigid-body dynamics or contact constraints. This exposes a critical physics gap: standard temporal smoothing applied on top of single-step or chunked VLAs trades trajectory quality for added failures that short-term memory cannot resolve. To bridge this gap, we introduce PhysVLA (Physics-VLA), a plug-and-play, inference-time framework designed to wrap any frozen VLA backbone without retraining, fine-tuning, or weight access, with less than 1 ms of overhead per control step. PhysVLA intercepts the predicted control action, captures only the simulator or system state, and applies a dual-layered correction: (i) a phase-aware finite-state machine that structures discrete task segments (approach, grasp, transport, and place), and (ii) a selective Euler-Lagrange gate that activates only when a dynamics oracle detects kinodynamic inconsistency. Evaluated across OpenVLA, OpenVLA-OFT, Force-VLA, and Generalist-VLA on LIBERO-Spatial with a 7-DoF Franka Panda, the framework delivers absolute success rate increases of up to 17% and stability increases of up to 19% with no per-task regressions, improves trajectory efficiency by up to 15% across all four backbones, and shows up to a 10x improvement in trajectory jerk robustness on a Robosuite Lift cross-simulator sweep. We further validate the framework on a real Agilex Piper arm with a pick-and-place task, confirming that PhysVLA transfers to physical hardware without retraining, with success-rate improvements of up to 50%, establishing physical awareness as a composable, backbone-agnostic runtime module.