DexNinja: Learning Robust Dexterous Cutting Policy with a Real-to-Sim-to-Real Data Engine

Collecting real-world robot data for dexterous manipulation is costly and time-consuming. While high-fidelity physics simulators enable scalable data synthesis and policy learning, constructing deployment-ready digital twins manually remains labor-intensive, and residual visual, geometric, and dynamics gaps hinder reliable sim-to-real transfer. We present DEXTERA, an automated real-to-sim-to-real framework that transforms a single RGB image into deployable policies for dexterous manipulation across four unified stages: (1) single-image scene factorization into a static Gaussian background and interactive rigid or articulated assets with VLM-inferred physical parameters; (2) metric scene global alignment, object canonicalization, and morphology-balanced robot calibration; (3) scalable simulator task primitive construction, VR teleoperation, and object-centric trajectory synthesis; and (4) a shared multimodal policy interface supporting both imitation learning and reinforcement learning. We evaluate DEXTERA across 13 task-embodiment pairs, 2 dexterous robot platforms, and 6 policy architectures. Experimental results demonstrate that DEXTERA achieves superior visual fidelity and 3D geometric reconstruction compared to generative baselines, while cross-domain trajectory replays validate strong physical interaction consistency. Furthermore, simulation-only trained policies enable viable zero-shot real-robot deployment, while simulation-real co-training substantially improves mean physical policy success from 29.2% to 61.9% across diverse policy architectures. Project website: https://dextera-project.github.io/

Sim-to-real transfer remains a critical bottleneck for deploying dexterous manipulation policies learned in simulation to real-world robots. Existing approaches rely on manually designed domain randomization or task-specific adaptation, limiting their generalizability across diverse manipulation scenarios. We present DexSim2Real, an integrated framework that leverages vision-language foundation models to bridge the sim-to-real gap for dexterous manipulation. Our system combines three components: (1) Foundation Model-Guided Domain Randomization (FM-DR), which uses a vision-language model as a visual realism critic to optimize simulation parameters via closed-loop CMA-ES, complementing text-based approaches like DrEureka with direct visual feedback; (2) a Tactile-Visual Cross-Attention Policy (TVCAP) that adapts cross-attention visuo-tactile fusion to zero-shot sim-to-real RL; and (3) a Progressive Skill Curriculum (PSC) that builds on LLM-based task decomposition with a difficulty scheduler tailored to contact-rich dexterous tasks. Extensive experiments on six challenging manipulation tasks with blinded evaluation demonstrate that DexSim2Real achieves a 78.2% average real-world success rate, outperforming DrEureka and DeXtreme while reducing the sim-to-real performance gap to only 8.3%.

Dexterous manipulation policies trained in simulation often fail to transfer to the real world because of errors in contact timing and force regulation. Yet these policies can retain useful multi-finger coordination for task progression. We propose ReDex, a framework for adapting a simulation-trained base policy to the real world by correcting local contact failures and incorporating tactile feedback. Starting from a proprioception-only base policy, ReDex allows a human operator to physically correct contact failures at selected fingers under compliant control during real-world rollouts, while the frozen base policy continues to control the remaining fingers. These rollouts combine base policy execution, human-corrected finger motion, and fingertip force observations. We reconstruct force-informed targets from these rollouts to train a standalone force-conditioned policy via behavior cloning. This design reduces human correction effort, enables learning of contact regulation from real-world interaction, and introduces force feedback into a proprioception-only policy without tactile simulation or complex full-hand teleoperation. We evaluate ReDex on two challenging, contact-rich dexterous manipulation tasks on real hardware. Compared with sim-to-real transferred base policies, ReDex increases Object Flipping success rate from 14% to 86% across two objects and average Screwdriver Rotation progress from 26.0% to 95.3% across three objects.