Contact-Rich Robotic Manipulation in Construction via Zero-Shot Learning: A Diffusion Policy-Guided Adaptive Control

Real-world robotic assembly at sub-millimeter tolerances demands spatial precision, compliant interaction, and robustness to contact failures. We present Facet-0, a robotic foundation model that predicts and values the contact consequences of its actions. Facet-0 unifies multimodal representation learning and reinforcement learning (RL) post-training around a joint action-wrench proposal: a causal wrench history is aligned with vision-language semantics and kinematic state, and flow matching generates each action chunk together with the future wrist-wrench profile it is expected to induce. Deployment rollouts train a distributional Action-Wrench Critic to distinguish motions with similar task progress but different contact outcomes, while phase-aware rewards and contact-selective credit concentrate policy improvement on decisive interactions. To accommodate part-specific dynamics, a lightweight bounded actor reuses the frozen representation for on-robot adaptation; RL remains defined over executable Cartesian actions, while an auxiliary wrench head preserves predictive, non-commanded action-contact coupling. Trained on ManuFacet-1K, a 1,000-hour force-synchronized corpus spanning three embodiments and multiple manufacturing cells, the bounded task-adapted system reaches 82% mean success on five sub-millimeter computer-assembly tasks, compared with 15% for the strongest baseline, with 0.5 mm placement accuracy and 50 ms command latency.

Contact-rich assembly remains challenging because it requires submillimeter spatial accuracy and reliable interpretation of forces during sustained contact. Although simulation-based reinforcement learning offers a scalable training paradigm, discrepancies in visual observations, contact dynamics, and force/torque (F/T) measurements often limit policy transfer. We observe that proprioception is comparatively consistent across domains because joint positions are expressed in a shared calibrated coordinate system and joint velocities are computed consistently in simulation and on hardware. Based on this observation, we present PACE (Proprioception-Anchored Cross-Modal Encoder), which supervises temporal visual and F/T representations by predicting proprioceptive state transitions. Static domain-specific factors, including lighting, texture, and sensor bias, contain little information about joint motion; optimizing the proposed objective therefore suppresses their influence on the learned representation while retaining task-relevant motion cues. Policies trained on frozen PACE features are directly deployed on hardware without real-world fine-tuning or object-pose tracking. Across four contact-rich assembly tasks, PACE attains an average real-world success rate of 93.3% and only a 2.7-percentage-point sim-to-real drop, while remaining robust to perturbations that substantially degrade pose-based and learned-fusion baselines.

This paper presents a novel autonomous robotic assembly framework for constructing stable structures without relying on predefined architectural blueprints. Instead of following fixed plans, construction tasks are defined through targets and obstacles, allowing the system to adapt more flexibly to environmental uncertainty and variations during the building process. A reinforcement learning (RL) policy, trained using deep Q-learning with successor features, serves as the decision-making component. As a proof of concept, we evaluate the approach on a benchmark of 15 2D robotic assembly tasks of discrete block construction. Experiments using a real-world closed-loop robotic setup demonstrate the feasibility of the method and its ability to handle construction noise. The results suggest that our framework offers a promising direction for more adaptable and robust robotic construction in real-world environments.