Function-Preserving Data Generation for Zero-Shot Real-to-Sim-to-Real Manipulation
Authors: Tianyi Xiang, Xupeng Xie, Jiahang Cao, Andrew F. Luo, Haoang Li, Jun Ma
Abstract
Robotic data generation is a promising paradigm for scaling robot learning without collecting large-scale real-world data. However, generating geometrically diverse yet physically valid data for contact-rich tasks remains challenging, especially when success depends on precise geometric interfaces. Standard shape augmentation methods often distort task-critical interfaces, resulting in invalid contact relationships, e.g., fit mismatches or interpenetration, rendering downstream interactions infeasible. To address these limitations, we propose a function-preserving Real-to-Sim-to-Real framework that generates synthetic demonstrations from reconstructed assets without teleoperated source trajectories. Our method augments task-relevant object geometries through constraint-guided mesh deformation, together with physically consistent transfer of task poses and collision proxies. Visual domain randomization is further applied during simulation rollouts, enabling robust zero-shot policy deployment without real-world fine-tuning. Extensive experiments in both real-world and simulation settings demonstrate that our method enables robust generalization across unseen object geometries and diverse visual conditions in contact-rich and long-horizon tasks. Our method provides a practical path toward scalable robot learning for contact-rich tasks via shape deformation.
Scaling data volume and diversity is critical for generalizing embodied intelligence. While synthetic data generation offers a scalable alternative to expensive physical data acquisition, transferring robotic manipulation policies from simulation to the real world (sim-to-real) remains a formidable challenge due to the domain gap. This paper presents HyperSim, a holistic framework spanning from synthetic data generation to policy training and seamless real-world deployment. To systematically bridge the sim-to-real gap, HyperSim is realized through three core pillars: high-fidelity environment synthesis, adversarial trajectory generation, and sim-and-real co-training. Collectively, these modules address domain discrepancies by enhancing visual fidelity, expanding data coverage, and enforcing domain-invariant representations. We rigorously validate HyperSim through a large-scale empirical study involving 400 real-world task executions across two representative manipulation models. Assessed across three fine-grained metrics, our complete pipeline achieves remarkable sim-to-real success rates of 80% and 95% with ACT and π_{0}, respectively. Furthermore, policies trained on our adversarial trajectories exhibit significantly enhanced robustness against dynamic uncertainties, achieving a 35% higher completion rate under physical perturbations.
Manipulation policies deployed in uncontrolled real-world scenarios are faced with great in-category geometric diversity of everyday objects. In order to function robustly under such variations, policies need to work in a category-level manner, i.e. knowing how to interact with any object in a certain category, instead of only a specific one seen during training. This in-category generalizability is usually nurtured with shape-diversified training data; however, manually collecting such a corpus of data is infeasible due to the requirement of intense human labor and large collections of divergent objects at hand. In this paper, we propose ShapeGen, a data generation method that aims at generating shape-variated manipulation data in a simulator-free and 3D manner. ShapeGen decomposes the process into two stages: Shape Library curation and Function-Aware Generation. In the first stage, we train spatial warpings between shapes mapping points to points that correspond functionally, and aggregate 3D models along with the warpings into a plug-and-play Shape Library. In the second stage, we design a pipeline that, leveraging established Libraries, requires only minimal human annotation to generate physically plausible and functionally correct novel demonstrations. Experiments in the real world demonstrate the effectiveness of ShapeGen to boost policies' in-category shape generalizability. Project page: https://wangyr22.github.io/ShapeGen/.
RGB sim-to-real for deformable manipulation has remained largely unsolved without real-world fine-tuning. We present SimWeaver, which trains zero-shot RGB VLA policies on 200 simulated demonstrations per task, reaching above 80% per-task and 91% average real-world success across 5 diverse deformable tasks including plastic-bag manipulation, without teleoperation or per-task calibration. SimWeaver combines a reliable measurement-backed simulator (SimWeaver-Sim) with an extensible asset framework supporting single-image generation(SimWeaver-Asset), a deterministic topology-aware trajectory synthesizer (SimWeaver-Syn), and a sim-to-real protocol with ISP-aware photometric augmentation (SimWeaver-Real). On silk grasping, the sim-trained policy reaches 100% under visual distribution shifts where real-data baselines drop to 9-70%, at two orders of magnitude lower per-trajectory cost. We will release SimWeaver and a representative asset subset. Project page: https://simweaver.github.io/