Robotic Assembly

Transitioning from a digital design to a robotic assembly process currently requires months of expert manual tuning to reconcile part geometries with robotic constraints. This paper presents an end-to-end, autonomous pipeline for the design and physical construction of bespoke wooden assemblies. A generative AI agent translates user prompts into initial 3D geometries, balancing the visual fidelity of the design with select physical constraints. The assemblability of the design is further improved by a gradient-based repair stage that backpropagates through a graph attention network surrogate to adjust component geometries. In addition to correcting for disjointed and overlapping components, we demonstrate hardware-specific corrections, differentiably optimizing the geometry of components to enable robot screwdriving for 86.7% of 60 novel natural language inputs, significantly outperforming prior work by a factor of ten. For ten of the structures, we physically demonstrate assemblability with two UR5e robots. This work marks a meaningful step toward on-demand robotic manufacturing, enabling the rapid production of customized, low-volume goods.

Automated insertion of board-to-board (BTB) connectors in 3C manufacturing requires both high visual accuracy and strong deployment robustness. This problem remains challenging because multi-variant connectors exhibit significant morphological and appearance variations, making stable cross-variant generalization difficult, while the mismatch between training and deployment under fixed-view inspection settings induces background spurious correlation and degrades real-world performance. To address these issues, this paper proposes MCFR, a Mask-Guided Coarse-to-Fine Regression framework for multi-variant BTB connector assembly. By introducing an object-aware mask prior and explicit photometric refinement, the proposed method suppresses background interference and improves alignment accuracy and robustness in practical deployment. Experiments on a self-constructed multi-variant dataset, a BTB batch insertion testbed, and a real smartphone assembly task show that MCFR consistently outperforms representative baselines and achieves an average real-world insertion success rate of 99.25%. These results demonstrate the effectiveness and practical potential of MCFR for automated assembly of multi-variant BTB connectors.

Pose error in precision assembly can corrupt not only what a robot observes but also the coordinate frame in which it acts. On the FORGE benchmark, the official state-based policy succeeds in 97% to 99% of episodes with the true pose but only 32% to 60% at the benchmark's $σ=5$ mm pose-noise setting. The same estimated pose enters the observation and anchors the action frame, making the offset unidentifiable from proprioceptive state alone before contact. We supply this missing information during training in two ways. A privileged teacher observes the offset in simulation, while clean demonstrations can instead be relabelled into the displaced frame in closed form. The deployed student is trained with behaviour cloning followed by one DAgger round and receives only noisy state, a raw wrench window, and two RGB cameras at test time. On the unmodified FORGE tasks, the teacher-route student maintains 92% to 99% success across $σ=0$ to 5 mm, while six non-privileged baselines fall to 2% to 80%. A matched behaviour-cloning experiment isolates the source of this robustness. With the same student architecture, data budget, and training procedure, demonstrations generated without offset access yield only 31.5% success at $σ=5$ mm, whereas privileged and relabelled demonstrations reach 88.7% and 95.8%. Deployed zero-shot on a Franka, the student reaches 83.3% pooled success at $σ=5$ mm against 34.4% for the strongest state-based policy. Deployable sensing alone is insufficient. Robustness requires supervision that encodes compensation for the latent frame offset.Project page: https://drychang.github.io/displaced-frame/

Autonomously constructing physically realizable 3D structures remains a significant challenge due to combinatorial action spaces, interchangeable components, equifinal assembly sequences, and strict stability requirements during construction. State-of-the-art methods fine-tune large language models for text-based generative construction. However, these approaches do not allow for Multimodal (text, image, sketch) conditioning, overlook the practical role of scaffolding for stabilizing intermediate structures, and suffer from slow inference speeds. Therefore, we formulate construction as a probabilistic next-block generation task with multiple potential assembly actions and multiple potential task conditioning modalities. Concurrently, we explicitly consider the utility of scaffolding by introducing an auxiliary scaffold block token. We present Scaffold Multimodal Monte Carlo (ScaffoldM3C), a multimodal, lightweight, auto-regressive model for stable block-based construction, that proposes a set of next-step candidate blocks. Leveraging these candidates, we utilize Sequential Monte Carlo (SMC) to maintain a population of possible assembly sequences, allowing us to consider multiple, potentially different, assembly directions simultaneously. We train our multimodal architecture by extending the StableText2Brick dataset to contain image conditioning prompts and scaffold-stabilized build sequences. ScaffoldM3C is 4x smaller than competing baselines, yielding a 5x to 20x speedup during inference, while achieving comparable construction quality to state-of-the-art methods and higher overall stability. We demonstrate the effectiveness of our approach through simulations and real-world robot assembly demonstrations.

The task of 3D assembly requires translating an understanding of parts and their relationships into precise spatial arrangements. Can pretrained general-purpose agents assemble objects through visual interaction without additional assembly-specific fine-tuning? To investigate this question, we introduce AssemblyWorld, an interactive 3D environment in which agents inspect rendered views and manipulate supplied rigid parts, guided by images or assembly manuals when available. Agents perceive part geometry through 2D views rather than direct access to mesh vertices or faces, while their resulting assemblies are evaluated geometrically. Building on this environment, we construct AssemblyWorldBench, comprising 100 assembly tasks across 80 objects spanning furniture, industrial assembly, and fracture reassembly. Evaluating eight agent systems reveals substantial differences in their capabilities. The strongest system achieves 80.9% part accuracy but 59.4% complete-assembly success. The evaluated open-source systems lag substantially behind their stronger closed-source peers in both execution reliability and assembly accuracy. Analyses of visual references, interaction trajectories, and failures show how agents revise assemblies while leaving residual positioning errors. AssemblyWorld provides a common setting for both assessing the capabilities of interactive assembly agents and characterizing the gap between approximate structure recovery and precise reconstruction.

Assembly using robots often requires specially designed fixtures, or relies on top-down only assembly strategies. Using multiple robots, we can avoid using fixtures and make robotic assembly more flexible. Planning assembly sequences for multiple robots is challenging due to the high number of possible task assignments and orders. In addition, we need to reason over forces that occur during the assembly process, e.g., to decide if multiple robots are required for support, or if external support such as a table should be used. We present Wrap, a multi-robot assembly planner for multi-part assemblies, given the inter-part ordering-dependencies, the part meshes, and their initial state. We formulate a linear program to reason about valid grasps for supporting the forces that occur during assembly. The search leverages the assembly sequence, and greedily finds a feasible solution per assembly step by computing a heuristic via a cheap backwards search, and using the heuristic in the more expensive forward search. We then solve the multi-robot, multi-goal motion planning problem, and for execution, we split the plan into contact-rich assembly skills, and free space motion. We benchmark the planner on a variety of multi-part assemblies, and apply the planner to groups of robots differing in size and kinematics. We validate the work both in a physics simulation, and in real. Videos and code are available at https://www.vhartmann.com/wrap.

We present VGM-VS, a visual servoing method built on a pretrained feed-forward visual geometry model. Given the current view and a reference image captured at the target configuration, we estimate the relative camera pose with a visual geometry model and apply it iteratively as the pose increment of a closed-loop pose-based visual servoing (PBVS) scheme. The geometry-aware representation acquired from large-scale pretraining keeps this estimate reliable when the target is occluded, weakly textured, or covers only a small part of the image. However, the scale ambiguity inherent to these models leaves the predicted translation defined up to an unknown scale, while the pose increment must be metric for robot control. We close this gap with a scene-specific metric adaptation: the robot autonomously records image--pose pairs along a predefined motion starting from the target pose, and we fine-tune the camera head on these data, jointly learning the hand--eye transform and thus removing the need for a dedicated calibration process. We evaluate our method on three real-world assembly tasks with demanding tolerances: USB-C cable picking, cable insertion, and RAM insertion. Running in real time at 30Hz, VGM-VS converges to submillimeter terminal accuracy on the cable tasks, and reaches success rates of 90--100% when the target is moved during servoing. It converges in all trials under initial displacements of up to 30cm from the reference pose and with 50% of the target object occluded, outperforming the compared visual servoing baselines.

Robotic assembly in high-mixture settings requires adaptable systems that can handle diverse parts, yet current approaches typically rely on policies specialized to each insertion task. Although this can reach high success rates, it makes the process of deploying systems for new problems tedious and time consuming. We present a framework for generalizable insertion using world models that combine robot proprioceptive information with raw visual observations captured by a wrist-mounted camera. Our model-based approach trains a single world model on up to 90 insertion tasks with geometrically diverse parts, achieving 56% zero-shot success on unseen objects with unknown geometry compared to just 7% with a model-free baseline. Importantly, performance improves as more objects are included in the training dataset, demonstrating strong scalability. Lastly, finetuning the generalist model on held-out objects significantly enhances data-efficiency compared to training from scratch and, in some cases, achieves better asymptotic performance. To our knowledge, this is the first system capable of assembling unseen objects in an entirely data-driven manner, and thus represents a significant step toward scalable, generalizable robotic assembly systems.

Robots have significant potential to automate construction processes. However, their industry adoption remains limited, partly because of the programming effort required to adapt robots to diverse tasks. This paper presents a skill sequence planning method that enables a heterogeneous team of multi-functional robots to collaboratively perform construction assembly work using reusable, preprogrammed skills such as grasping, drilling, and fastening. A central controller transforms the digital representation of the building into a construction relationship graph that represents construction entities, their states, and their parent-child relationships. Based on this representation, the system selects the next construction target, generates a symbolic sequence of skills for capable members of the robot team, and produces collision-free geometric motion plans for skill execution. The symbolic planning problem is dynamically regenerated as the construction state changes. An interactive digital twin presents the planned skill sequence and robot states to human co-workers for review and approval before execution. The method is evaluated through a construction assembly case study. By reducing the need to program robots separately for each task variation, the proposed approach supports more flexible deployment of collaborative robot teams in construction.

Multi-robot systems have shown increasing viability in construction due to their ability to execute high-precision actions while reducing human exposure to hazardous tasks. However, these environments have high-dimensional configuration spaces and possess substantial collision-avoidance constraints, which include other robots, assembly objects, and workspace boundaries. We utilize a single factor graph for trajectory estimation and planning that incorporates measured robot states together with explicit collision and learned cable constraints. This supports changing workspaces and enables synchronized, high-dimensional robot motion planning while accounting for the stiff, vibration-induced uncertainty of heavy robotic systems. We demonstrate the success of our framework on the construction of a post-and-lintel structure using one robot arm as a timber gripper, and a second robot as a nail-fastener.

Robots inspecting an assembly must determine which parts are present and whether they are correctly installed. During egocentric assembly assistance, head motion and workpiece handling reveal evidence for these checks, while spoken state confirmations link observations to procedural outcomes. We introduce INSPECT, which learns robot view preferences from records of a smart-glasses assistant that answers part queries and provides next-step guidance. Presence-Invariant TwinSwap (PI-TwinSwap) calibrates object evidence through paired identity interventions. Claim-indexed supervision separates evidence requirements from camera-reproducible observation changes. Object-centered calibration adapts relative view preferences to robot poses, while clause-level screening checks predicted evidence. The robot selects views using only its current observation and known poses, without candidate images. Evaluation uses annotated assistant-video replay to simulate state feedback, without target-domain view labels for policy training. On images of physical gearbox assemblies, INSPECT achieves the highest view utility among the compared non-oracle policies and raises human-rated full verifiability from 34.8% to 41.7% compared with keeping the current view. On commercial angle-grinder recordings in IMPACT, the transferred relative-view selector increases the correct decision rate from 50.6% to 54.3% with a frozen perception head. The source code is available at https://github.com/Kratos-Wen/INSPECT.

Assembly Sequence Planning (ASP) remains a challenging problem due to its combinatorial nature, making exhaustive planning approaches impractical for complex industrial assemblies. Furthermore, many CAD models lack reliable semantic contact information or require extensive manual preprocessing, limiting the applicability of existing methods. This paper presents a hybrid ASP framework combining learning-based relation extraction with geometric-symbolic reasoning to generate feasible robotic disassembly sequences from imperfect CAD data. A neural network predicts semantic geometric relations from point clouds, while human-in-the-loop verification enables correction of uncertain predictions and planning failures. Extracted relations are transformed into a symbolic assembly graph, enabling a geometric-symbolic planner to efficiently compute locally valid sets of robotic manipulation primitives. A visibility-based ray-casting strategy guides the search for feasible disassembly directions without requiring an exhaustive combinatorial search, while the local solution space enables efficient sequence optimization. The framework is evaluated on an introduced assembly dataset and on the ASAP test dataset. On the ASAP test dataset, the proposed planner achieves an 85.83% planning success rate while reducing the median planning time by more than one order of magnitude across all assembly sizes and by more than a factor of 50 for assemblies with more than 30 components compared to the baseline. The results demonstrate that the proposed hybrid framework enables efficient robotic assembly sequence planning from imperfect CAD data while substantially reducing planning time. By combining learning-based feature segmentation, human-in-the-loop verification, and geometric-symbolic reasoning, the framework provides a practical foundation for scalable and adaptable robotic assembly and disassembly planning.

The introduction of human-robot collaboration (HRC) in industrial assembly operations is revolutionizing the manufacturing landscape. In this evolving environment, operators are required to seamlessly coordinate their manual tasks with real-time task information and robotic behaviors. These demands fluctuate during operation, yet conventional workload assessments depend on body-worn physiological sensors that complicate practical deployment. Here, we present a vision-based attention--action framework for continuous and interpretable workload-related assessment in HRC assembly. The framework combines RGB-D observations with robot states and calibrated task-related areas to construct a temporally confirmed representation of operator behavior. This representation identifies where task demand is concentrated and explains how it develops when attention and action diverge, the task context changes, or the operator hesitates. We evaluated the framework in a three-level collaborative gearbox assembly experiment with ten participants, using subjective ratings and synchronized physiological signals as independent references. Raw NASA-TLX ratings confirmed increasing perceived workload across conditions, with significant effects on overall workload and its mental and temporal dimensions. The vision-derived HRC-CWL output was significantly associated with ECG-derived features in seven of nine participants with complete correlation data. Synchronized interaction episodes further showed temporal correspondence between detected hesitation and physiological activity. Real-time deployment demonstrated that the framework can operate without requiring operators to wear additional sensors. These findings support HRC-CWL as an interpretable behavioral proxy for cognitive ergonomics analysis and adaptive robot assistance, rather than a direct psychophysiological measure of workload.

A hallmark of human dexterity is the cooperative use of fingers, where different fingers take on distinct yet coordinated roles to accomplish fine manipu- lation, such as capping a pen with the hand that holds it. We study this finger-level coordination through in-hand assembly: mating two rigid objects within a single dexterous hand, with no second arm and no fixture. We present a reinforcement learning formulation to solve this problem in a unified framework, which is driven by a goal relative pose between the two parts. Finger coordination is shaped by a function-based auxiliary reward and regularized toward a single human reference pose, while domain randomization and a fusion of historical proprioception and object observation confer robustness to occlusion-induced estimation noise. The same recipe solves three different assembly tasks (Bottle, Syringe, and Marker). Trained purely in simulation, the policies transfer zero-shot to hardware with a single camera, demonstrating robustness to state-estimation errors caused by oc- clusion. Our experiments also reveal that in-hand assembly places demands on hand morphology and can serve as a benchmark for modern robotic hand systems. Videos and code are available at https://ltbgbird.github.io/in-hand-assembly-page/.

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.

Learning-by-Demonstration (LbD) enables intuitive robot programming by capturing expert skills, which is crucial for agility in high-mix, low- volume manufacturing. This systematic literature review analyzes passive LbD for industrial assembly processes, focusing on the perception architecture and the generalization of the perceived demonstration. We specifically investigate one-shot approaches where only a single demonstration is required. The review evaluates how systems adapt to new assemblies using this limited data. We identify a shift towards object-centric perception, allowing learned primitives to be transferred to new product variants with minimal training.

Highly varying production sets increasing challenges for robotic manufacturing and indoor logistics. New capabilities for agility, flexibility, and robustness are needed. Robot skills, integrating motions, tool operations, and sensor perceptions consistently provide an execution mechanism for a versatile set of tasks with varying parameters. In this paper, easy-to-use CAD-model based programming and execution system for parametrized skills and skill monitors is showcased. The execution control structure is dynamic and parametrized, based on a modified Behavior Tree, where only event based communication is used. A human-robot-crane collaborative skill is shown as a test example, where a human instructs an overhead crane and a manipulator in inserting a heavy object supported by the crane, and guided by the manipulator, into the goal.

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.

This paper presents a sensor-minimal automated assembly system for bidirectional single-row flat ribbon cable harnesses (FRCHs). Unlike conventional peg-in-hole or single-terminal insertion tasks, FRCH assembly involves mechanically coupled multi-terminal insertion under flexible and dense geometric constraints. To address this problem, the proposed system performs the assembly through a purely mechanical sequence consisting of Cable Alignment, Lean & Slide, Weaving, and Clamping, without relying on active sensing or vision. Each mechanism is designed to progressively reduce correlated terminal misalignment, insertion interference, and instability before final locking. Experiments on bidirectional single-row FRCHs achieved an 83.75% end-to-end process success rate over 80 trials, with success rates of 85.0% and 82.5% in the first and second halves, respectively. The cycle time was 33 s under half-speed operation. To the best of our knowledge, this work presents the first automated prototype for FRCH terminal-to-housing assembly for multi-pin housings.

Robotic construction systems often treat the material system and the robot as separate design problems, locating intelligence primarily in hardware, sensing, motion planning, and control. This project instead investigates how geometric intelligence can be encoded within architected material systems to simultaneously address requirements for robotic grasping, self-alignment, reversible connection, structural performance, and three-dimensional aggregation. We introduce a self-aligning compound nested lattice module composed of conjoined cuboctahedral-octahedral units. The cuboctahedral features of the modules provide defined surfaces for robotic grasping and alignment, while the octahedral features incorporate screw-releasable snap-fit connectors and corresponding receptors. Additionally, we present a nested arrangement that enables interlocking aggregation along the x, y, and z axes. We demonstrate the system through furniture and architectural scale structures assembled using both a robotic arm and mobile assembler. The resulting configurations include seating, spanning structures, surfaces, and vertical frames. Compression testing of the compound module produced a stiffness of 4,556 N/mm, a maximum load of 3,445 N, and a compressive modulus of 17.5 MPa. The modules can also be disassembled and reused across different configurations, supporting reconfigurable and circular construction.

Accurate localization remains a key challenge in swarm robotics, particularly for self-reconfigurable systems that must identify relative positions to form diverse structures. Most existing approaches rely on external tracking infrastructure or high-cost sensors, which limit scalability and deployment in unstructured environments. In this paper, we propose a novel contact-driven localization method for modular robots that leverages only local communication through binary contact information (whether two robots are physically connected or not). To exploit these contact cues, we introduce a virtual-force framework in which robots iteratively refine their poses attracting toward dock-connected neighbors and repelling from non-connected ones. The method requires no external infrastructure and relies only on minimal onboard sensing. Simulations show effective localization during the assembly of towers and cantilevers, enabling accurate, scalable, free-form self-assembly.

While scaling laws for imitation learning have primarily focused on generalization in open-world settings, the relationship between data and precision in closed-world tasks like robotic assembly remains largely unexplored. This paper systematically investigates this relationship and introduces a novel scaling law. We find that to achieve a fixed success rate, the required number of demonstrations $N$ grows super-exponentially as the target precision $P$ approaches a limit $c$. This relationship is accurately captured by the model $\log(N) \propto 1/(P-c)$. Crucially, we reveal that the limit precision $c$ is not a static physical constant of the task but an emergent property of the entire agent system, including its sensors and expert policy. Through experiments on canonical manipulation tasks, we validate this law and demonstrate that improving system components, such as adding a wrist camera or using a more effective expert, measurably lowers $c$, thus expanding the system's achievable precision. Our work provides a new theoretical framework for precision in robotics and a quantitative metric to evaluate system capabilities. Furthermore, these findings provide a practical methodology for guiding the development and debugging of high-precision manipulation systems.

In production processes for consumer products, assembly instructions are essential not only for planning but also for executing the production process. Likewise in robotics, it is crucial for an assembly robot to understand how components fit together and can be assembled. To facilitate these tasks, we contribute a method for constructing scene graphs to represent and characterize assembly relationships between components. Our approach does not rely on semantic data and is capable of handling a very small dataset. To realize this, the output of a Faster R-CNN model is used to create geometric representations, which are then processed by a transformer architecture to generate an adjacency matrix. This matrix serves as input to a Siamese network that uses message passing based on an attentional graph convolutional network (aGCN) architecture to characterize the connections between the components. We validate our method on a study dataset of toy model components which can be assembled into transportation vehicles.

Force-conditioned reinforcement learning (RL) enables tight-clearance assembly under a commanded force ceiling, but practical deployment requires determining an appropriate force limit for each object and recovering from insertion failures without exceeding it. We present a two-layer framework in which a frozen, text-only large language model (LLM) assigns a per-object force ceiling before execution and selects recovery maneuvers from a fixed action menu using compact textual force signatures. The LLM never controls force directly: a low-level controller enforces the force ceiling, the recovery policy cannot increase it, and the hidden breaking-force threshold is known only to the evaluator. We evaluate the framework on fragile bottle placement and 0.4 mm diametral-clearance gear insertion using two grippers (Robotiq 2F-140 and Franka Panda hand). A single policy passes 256/256 evaluation episodes on both fragile and robust objects without breakage, correctly predicts release timing, and completes a full table-pick-and-insert pipeline with a mean peak force of 5.4 N. Under injected in-grip slip, the force-signature recovery strategy resolves 40% and 64% of failures on the two grippers, whereas a press-harder baseline is either ineffective or causes frequent breakage. We also report negative results, including the failure of PPO to solve the task under strict force constraints and unsuccessful learned release strategies. All experiments are conducted in rigid-body simulation with hidden force-threshold breakage; no sim-to-real claim is made.

Motion planning for rigid-body assembly poses a fundamental challenge in robotics due to tight geometric constraints. In such scenarios, feasible motions often require passing through (near-)zero clearance configurations in which the parts are tightly constrained by contact. In this work, we introduce Critical-Manifold Guided RRT (CMG-RRT), a sampling-based planner designed specifically for tight assembly problems. Our key observation is that in tight assemblies, valid solution paths lie on or near a critical manifold: the subset of configuration space consisting of poses with at least one contact point between parts. CMG-RRT guides exploration by adaptively biasing sampling toward neighborhoods of the critical manifold using a hierarchical subdivision of the configuration space. We prove that CMG-RRT is probabilistically complete under standard clearance assumptions. Empirical evaluation on challenging rotational assembly benchmarks demonstrates a 100% success rate across all tested instances, including, to the best of our knowledge, the first fully automatic solution of the Elk disentanglement puzzle. Our open source software is available through our project page: https://www.cgl.cs.tau.ac.il/projects/tight-assembly-planning.

We provide a novel end-to-end framework for the execution of an assembly operation by two robotic arms, given the digital CAD models of the parts and their desired relative placement in their assembled state. We analyze and demonstrate the advantages of using two robotic arms simultaneously in tight assembly operations, compared to single-arm systems. Our method is implemented in both simulation and using physical robots. It provides theoretical guarantees on execution time and trajectory accuracy, supported by empirical evidence. In particular, we show that coordinated movement of two arms reduces average execution time by more than 50% compared to using a single arm only, produces higher-quality trajectories, and accelerates the search for valid robot placements. Furthermore, we establish bounds on the required dimensions of the robotic cell. Our open source software together with real-life video demonstrations are available in our project page.

Vision-Language-Action (VLA) policies offer strong general-purpose manipulation priors, but often fail on tight-tolerance, contact-rich assembly due to long-horizon credit assignment and subtask coupling: a state that is geometrically successful for the current skill can be brittle for downstream skills. We show this failure mode in residual reinforcement learning (RL) over a frozen VLA base policy: constant sparse success rewards improve each subtask in isolation yet yield little or no gain when skills are chained, because terminal state quality is uncontrolled. We propose Foresight Residual RL, which optimizes handoff quality by augmenting each subtask's sparse success reward with an offline-estimated foresight value -- the probability of future subtask success conditioned on the terminal state of the current subtask. Concretely, we (i) train a visual foresight predictor from images of terminal states of the base policy, labeled using downstream rollout statistics, and (ii) train residual policies via backward foresight induction, using the predictor output as a reward multiplier. On a three-phase wrench-based nut-tightening assembly task in Isaac Gym (grasp, move-insert, rotate), our method achieves 85.6% full-task success, outperforming standard subtask residual RL (54.5%) and VLA baselines, while leaving per-subtask success unchanged. These results highlight that improving long-horizon performance requires shaping which successful states are produced at each sub-task, not only whether success occurs.

Current work on robot furniture assembly mostly focuses on toy-scale settings or single-arm manipulation. We introduce FurnitureVLA, the first systematic study of real-scale bimanual furniture assembly using Vision-Language-Action models (VLAs). We formalize the task, develop a scalable simulation pipeline for expert data generation and evaluation, and build a VR teleoperation system for single-operator bimanual control to collect high-quality real-world demonstrations. To address extreme long-horizon assembly with up to 7 subtasks and 1550 control steps, we propose a progress-enhanced VLA, finetuned on semantically grounded subtasks, that jointly predicts actions and a continuous progress signal, enabling automatic subtask transitions and reducing compounding errors during inference. We further study perception and control design factors that critically affect precision in real-scale assembly. FurnitureVLA improves average simulation success from 48% to 80% compared to baselines across three furniture types, with an additional 21% gain from our design factor study. We validate on a real Kinova Gen3 platform with only 16% drop on the hardest task.

Multi-fingered robots promise the speed and dexterity of human hands, yet challenging problems such as precise assembly have remained out of reach. These tasks are contact-rich, making data collection for imitation learning difficult, and sparse-reward, making direct exploration with reinforcement learning (RL) intractable. Consequently, prior work has made progress by structuring the problem with specialized grippers, tool attachments, and environment fixtures. In this work, we argue that before a robot can perfect precise assembly, it must first learn to play. We further ask the question: what factors in the process of learning to play matter for precise assembly? We propose Play2Perfect, an RL framework for task-agnostic pretraining through play on diverse objects and goals, which is then perfected on precise assembly. The goal of play is to acquire reusable manipulation priors, such as grasping, in-hand reorientation and pose reaching. Finetuning then adapts this general prior to assembly, focusing exploration on the final contact-rich, high-precision interactions needed for success. We systematically study key design choices in play pretraining, including object diversity, training objective, trajectory diversity, and goal precision. We show that our prior is 33x more sample-efficient than RL training from scratch, even when provided with dense, multi-stage rewards. We demonstrate zero-shot sim-to-real transfer, achieving 60% success on tight insertions with only 0.5 mm contact clearance, and over 50% success on long-horizon multi-part assembly and screwing.

Long-horizon, contact-rich complex manipulation tasks, such as seating a GPU into a PCIe slot, demand both millimeter high precision and out-of-the-box generalization to new tasks. Existing paradigms struggle to satisfy both: classical pipelines use brittle, task-specific interfaces to achieve high-precision control but require costly pipeline redesigns to adapt to new tasks, whereas monolithic end-to-end policies provide better generalization but lack high precision on complex, out-of-distribution tasks unless retrained with new data. Both paradigms share an implicit assumption: once a manipulation capability is acquired, it must be deployed as a rigid pipeline or monolithic whole, rather than being freely decomposed and recomposed. In this paper, we show that complex manipulation capabilities can emerge naturally from the composition of simple, independent behaviors. Rather than deploying a monolithic policy or a rigid pipeline, we propose CoStream, a framework orchestrating foundation models and diverse sensing modalities into multiple composable core behaviors: a semantic behavior extracting spatial constraints via foundation models; a predictive behavior forecasting trajectories by tracking keypoints in imagined videos; and a reactive behavior providing high-frequency tactile and force corrections. On a shared $SE(3)$ interface, these outputs compose by right-multiplication into a single pose command at each control step, executed by a compliant controller. We demonstrate CoStream on 8 real-world tasks spanning everyday manipulation and precision assembly, with the strongest gains in contact-rich assembly and object transfer, and show robust recovery from manual perturbations during execution. Website: https://costream-simple.github.io