Operational digital twin clinics enable task-based evaluation of embodied AI

Task success is not a sufficient measure of safety for embodied artificial intelligence (AI), because robots may complete objectives while violating safety requirements. Existing evaluations often emphasize performance and robustness, but lack a systematic route from documented safety hazards to executable, verifiable tests. We present EAST (Embodied AI Safety Testing), a digital-twin framework that converts literature-grounded safety evidence into fault-injection tests across perception, instructions, environments, actions, and timing. EAST combines an expert-reviewed safety-fault taxonomy and eight executable operators with applicability and validity constraints. Its three-stage workflow generates test specifications, verifies fault realization during simulated execution, and independently assesses safety challenges, violations, task outcomes, and behavioral signatures using simulator-state evidence. The framework preserves execution traces and replayable records, supporting attribution and reproducibility across experiments. We evaluate EAST on six RoboTwin manipulation tasks and two policy architectures, ACT and RDT, against alternative testing strategies under matched budgets. Across five comparative campaigns, EAST targets all 74 admissible task-policy-operator combinations and obtains valid evidence for 63, while achieving safety-challenge exposure rates close to Random-Legal and Rule-Based. Moreover, 82 valid EAST executions complete their tasks despite safety violations, revealing risks concealed by success-oriented evaluation. These findings support systematic, validity-aware, reproducible safety testing beyond task-completion metrics.

Deploying robots in unstructured real-world environments needs accurate, interactive models of the objects. Constructing these models at scale remains a critical bottleneck for robotic system integration. We present ArtiTwinSplat, a framework that automatically constructs articulated, photo-realistic digital twins of objects directly from RGB-D videos, requiring no CAD models, simulation assets, or manual annotations. Our method is built on 3D Gaussian Splatting that preserve geometric fidelity and photometric realism, coupled with an unsupervised articulation discovery pipeline that recovers part structure and joint kinematics from observed motion alone. With tracking and optimization stages our method provides stable, queryable digital twins that support real-time rendering, viewpoint control, and interactive manipulation. Unlike prior methods confined to simulation, ArtiTwinSplat operates directly on real-world observations and produces twins that are immediately usable by downstream robot planning and learning systems. This method offers a practical, scalable pathway toward digital twin construction, lowering the integration barrier for articulated object manipulation in embodied AI and human-robot collaboration contexts.

Training and evaluating robot policies in the real world is costly and difficult to scale. We introduce SimFoundry, a modular and automated system for zero-shot real-to-sim scene construction from a video. SimFoundry generates sim-ready digital twins and supports object, scene, and task editing, enabling the automated generation of diverse digital cousins: affordance-preserving variations of reconstructed real-world scenes. Policies trained on SimFoundry data transfer zero-shot to challenging real tasks involving multi-step manipulation, articulated object interaction, and bimanual interaction, and its digital cousins (variations of the original scene, objects, and tasks) facilitate generalization to new real-world conditions. Across 7 manipulation tasks and 5 policy architectures, SimFoundry simulation evaluations strongly predict real-world performance, with mean Pearson correlation 0.911 and mean maximum ranking violation 0.018. When evaluating sim-trained policies zero-shot in the real world, policies trained with object, scene, and task cousins in simulation show average task success rate improvements of 17%, 21%, and 40%, respectively. Additional details at https://research.nvidia.com/labs/gear/simfoundry/ .