WireSeg-32K: A Physics-Grounded Synthetic Dataset for Wire Instance Segmentation

Deformable linear objects (DLOs) such as wires, cables, and ropes are common in robotic manipulation tasks, yet simulating them with both visual realism and physical accuracy remains challenging. Existing visual simulation methods typically rely on procedural geometric primitives that lack physically grounded deformation behavior, while physics-based approaches with robot learning support often approximate DLOs as rigid-link chains or generic soft bodies, failing to accurately capture the bending, twisting, and shear mechanics of slender elastic structures. In this work, we introduce DeformX, a co-simulation framework that integrates a dedicated Cosserat rod physics engine with NVIDIA Isaac Sim, enabling DLO simulations that are both physically faithful and visually realistic. Our Cosserat rod engine simulates the dynamics and self-collisions of DLOs, and contact interactions with arbitrary free-form meshes. To achieve high-fidelity visualization, we employ mesh skinning to map discrete rod deformations onto imported CAD models. To the best of our knowledge, DeformX is the one of the first frameworks for DLO simulation that unifies realistic visualization, principled physics, and compatibility with robot learning pipelines. We demonstrate its versatility across synthetic data generation and policy learning for DLO manipulation, and validate visual and physical fidelity through comparisons against real-world experiments. Notably, fine-tuning Segment Anything Model 3 (SAM3) on DeformX-generated data yields a 10.2% mAP@75 improvement in real-image wire segmentation, and a rope-swinging policy trained entirely in DeformX achieves a mean target-hitting error of 6.6 cm on a UR5e manipulator in real-world trials, highlighting its strong sim-to-real transfer capability.

Myotubes are multinucleated muscle fibers serving as key model systems for studying muscle physiology, disease mechanisms, and drug responses. Mechanistic studies and drug screening thereby rely on quantitative morphological readouts such as diameter, length, and branching degree, which in turn require precise three-dimensional instance segmentation. Yet established pretrained biomedical segmentation models fail to generalize to this domain due to the absence of large annotated myotube datasets. We introduce a geometry-driven synthesis pipeline that models individual myotubes via polynomial centerlines, locally varying radii, branching structures, and ellipsoidal end caps derived from real microscopy observations. Synthetic volumes are rendered with realistic noise, optical artifacts, and CycleGAN-based Domain Adaptation (DA). A compact 3D U-Net with self-supervised encoder pretraining, trained exclusively on synthetic data, achieves a mean IPQ of 0.22 on real data, significantly outperforming three established zero-shot segmentation models, demonstrating that biophysics-driven synthesis enables effective instance segmentation in annotation-scarce biomedical domains.

Deformable Linear Objects (DLOs), such as wires and cables, are central to industrial assembly. Unlike rigid objects, whose state is captured by a 6-DoF pose, DLOs have an infinite-dimensional configuration space and deform continuously under contact with grippers, fixtures, and the workspace, making them a demanding benchmark for general dexterous manipulation. Despite their importance, policy development and comparison remain difficult: existing benchmarks are often tied to specific hardware setups, lack modular and customizable task assets, or study generic deformable-object tasks without the fixtures relevant to real-world industrial wire manipulation. Few benchmarks align simulation, real-world data, and shared evaluation protocols. To bridge this gap, we introduce WireCraft, a simulation benchmark for industrial DLO manipulation with configurable difficulty and assets, spanning three task families: connector insertion, clip routing, and channel seating. It supports two complementary DLO physics models, articulated and deformable, and the trajectories come from both simulation and a physical UR5. We benchmark reinforcement learning (RL), imitation learning (IL), and vision-language-action (VLA) policies under shared metrics. Privileged state-based RL solves a representative setting in each task family with over 82% success, confirming the tasks are well-posed. For connector insertion, however, the transition from reaching the socket to contact-rich alignment remains a key bottleneck for vision RL, IL, and VLA policies. These results indicate that industrial DLO manipulation, though tractable under privileged state, remains an open challenge for current vision-based learning. The benchmark, data, and tools will be open-sourced upon acceptance.