Robotic Assembly

Human Action Recognition (HAR) is frequently investigated in Human-Robot Collaboration (HRC) research to understand what actions have been performed and hence the state of a collaborative task. Accurately tracking an assembly state from HAR is however not fully investigated, and in realistic scenarios is not a trivial task. This research systematically investigates and compares methods for tracking assembly state using action recognition inputs. Investigations using two diverse datasets and five state tracking approaches, including logic-based, Hidden Markov Model (HMM), and neural network (NN) methods, show that optimal approaches are not uniform across different tasks and that different methods fail under different circumstances. Testing is performed using both simulated inputs with varying noise levels and realistic inputs from a HAR model. Results show NN and HMM methods can perform well in tasks with limited variability, but for other scenarios logic-based approaches can be more robust. Methods which model expected action duration are also important for tasks with repeated actions where no additional sensing is provided.

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.

Multi-pair robotic assembly in unstructured environments faces spatial interference and contact uncertainties. Existing paradigms fail to bridge cognitive decision-making and physical execution, as they either encounter state-space explosion and knowledge bottlenecks or suffer from logical hallucinations and topological conflicts. We propose an end-to-end neuro-symbolic framework that solves the challenge hierarchically: generating optimal subgraphs for each pair, decoupling generality from edge cases, and then resolving cross-pair interferences. Given an eye-on-hand RGB-D assembly scene, the framework extracts semantic instance identity and state while quantifying the scene for divergence calculation. For each pair, optimal subgraph is generated via LLM using barely basic actions to mitigate hallucinations. Supportive actions for edge cases are reasoned and inserted with a lightweight discriminator. Driven by the divergence between the quantified baseline and current scene, it is easily extensible at low cost. Augmented subgraphs are topologically coordinated into global sequences while preserving internal behavioral coherence. Dynamic behavior trees embedding atomic skills close the force-aware execution loop. Offline evaluation on 100 real-world scenes achieves 97.00% global executability, outperforming classical and state-of-the-art planners. Real-robot deployment on a UR3 arm attains 90% success rate with 0.5 mm tolerance under strong interference, demonstrating a unified and verifiable solution for complex autonomous assembly.

This paper presents Tessellated Biomes, a cyber-physical framework for the adaptive robotic construction and reconfiguration of modular multi-material assemblies. It challenges the linear lifecycle of standard construction by fusing (1) local microfactory fabrication, (2) discrete multi-material optimization, and (3) distributed robotic assembly into a unified circular process of spatial adaptation. The research details methods for the digital fabrication of self-aligning modular primitives in multiple materials (PLA, timber, and concrete) produced in local microfactories; the aggregation and optimization of these primitives into compression-based discrete structures; and the deployment of custom quadrupedal robots that collaboratively relocate material into realized physical aggregations. The framework is validated through the fabrication, optimization, and robotic assembly of discrete structures. Together, these results position Tessellated Biomes as a model for resilient, reconfigurable architecture.

In assisted teleoperation for human-robot collaboration, accurate intention prediction is critical for enabling timely and reliable robotic assistance during long-horizon manipulation and assembly tasks. These systems require continuous understanding of user behavior to recognize actions, anticipate intentions, and detect mistakes in real time. However, robot teleoperation demonstrations are costly and hardware-limited, whereas human demonstrations are easier to collect and provide rich temporal structure. To address this challenge, we propose an uncertainty-aware human-to-robot intention prediction framework that combines: (1) hierarchical transfer learning, where MS-TCN++ is pretrained on human hand demonstrations and fine-tuned on limited robot teleoperation data to capture low-level actions and high-level task intentions; (2) a conformal prediction module that provides frame-level prediction sets with statistical coverage guarantees for reliable uncertainty quantification and early intention estimation; and (3) VLM-guided segment correction, which selectively reviews low-confidence or temporally uncertain segments using visual and temporal context. The framework supports action recognition, temporal segmentation, intention anticipation, and mistake detection for assisted teleoperation. Experiments on robot assembly demonstrations with 22 action classes show that human-to-robot fine-tuning improves the robot test-set Edit score from 70.50 to 80.70 using only 16 robot demonstrations. Edit-safe VLM correction further improves frame accuracy from 45.21% to 46.42% and increases F1@25 and F1@50 while preserving the Edit score. These results show that human demonstrations provide scalable pretraining data for robust, uncertainty-aware robot action segmentation. Code and data: project website.

We dream of AI agents that can read arbitrary designs and construct real-world objects from reusable building blocks. As a first step toward this vision, we study whether multimodal large language models (MLLMs) possess the visual grounding and spatial reasoning capabilities required for brick assembly. We formulate brick assembly as a sequential decision-making problem, where each step involves two subtasks: brick selection, identifying the target brick from candidate components, and brick pose estimation, predicting where and how the selected brick should be placed. To support this study, we introduce BC-Bench (Brick Construction Benchmark), the first benchmark for evaluating MLLMs on assembly with diverse bricks. Experiments show that current state-of-the-art MLLMs remain far from reliable builders, struggling with fine-grained brick selection and failing at precise pose estimation. To bridge this gap, we propose Brick-Composer, a learning framework that equips MLLMs with assembly skills through three complementary signals: Human Design Sparks, which provide affordance-rich construction demonstrations; World Feedback, which grounds predicted actions in visual and physical consequences; and Synthetic Experience, which scales learning beyond existing object designs. Brick-Composer improves brick selection accuracy by over three times, substantially reduces pose estimation errors, and raises strict step-level assembly success from less than 1% to around 15%. After training, a Qwen-3-8B can correctly compose up to 42% of the steps for a complete object, suggesting that MLLMs can acquire assembly capabilities through targeted, physically grounded learning.

We introduceWorkBenchMark, a LEGO Duplo-based robotic assembly benchmark motivated by the RoboCup Smart Manufacturing League. Robotic assembly couples low-level manipulation with task-level symbolic reasoning under physical constraints, a combination that current end-to-end learning methods do not yet solve reliably. The benchmark provides 400 tasks across four complexity tiers. We provide an open-vocabulary perception, Assembly-by-Disassembly baseline solution. Our planning-based pipeline outperforms a modern vision-language-action approach across all tiers. The benchmark, simulation environment, and baseline implementation will be released openly to support the broader robotic assembly community.

When using reinforcement learning (RL) for contact-rich robotic manipulation, vision can provide task-relevant information that complements robot proprioception. However, vision-enabled policies tend to overfit to the visual conditions seen during training, limiting their robustness and transferability. We present a human-in-the-loop RL framework that employs teacher-student distillation to achieve robust performance across multiple task variants, trained entirely in the real world without requiring domain randomization or data augmentation. A vision-enabled teacher distills its knowledge into a vision-free student that relies solely on pose, twist, and wrench sensing, combining fast training with strong task generalization. On the real-world NIST assembly benchmark board, our approach achieves 95% overall success after approximately 50 minutes of training on 3 representative tasks, including robust generalization to 8 unseen task variants. Fine-tuning with distillation achieves full success on the most challenging task. We demonstrate that the resulting policies outperform baselines in both robustness and adaptability. Page: https://tuwien-asl.github.io/VE2VF/.

We present CoRMA(Contrastive Robotic Motor Adaptation), a context-based meta-adaptation framework that modifies RMA for force-dominant assembly. CoRMA replaces raw simulator-parameter adaptation with a compact 6D simulator-only semantic contact context describing contact onset, lateral engagement, guided transition, contact direction, and jamming. A deployable causal Transformer adapter infers this context online from force, proprioceptive, and action histories using semantic regression and a force-regime contrastive objective. At deployment, oracle context is removed and replaced by the inferred context, enabling within-episode adaptation without demonstrations, privileged inputs, or gradient updates. We evaluate CoRMA on PegInsert, GearMesh, and NutThread in Isaac Lab / Isaac Sim 5.0 and on a real Marvin arm. Compared with FORGE baselines that achieve high simulation success but degrade substantially on hardware, CoRMA retains higher verified real success under controlled target-pose noise. These results support semantic contact inference as a reusable adaptation interface within a related assembly task family, while broader unseen-task generalization and Real2Sim calibration remain future work.

Robotic assembly in architectural construction faces a persistent bottleneck: existing planners are either highly specialized, requiring prohibitive retraining for every new geometric design, or operationally inefficient, treating structural sequencing and kinematic motion as disjoint processes. We present EUPHORIA, a unified framework that achieves universal few-shot adaptability and dynamic efficiency through a hybrid optimization strategy. To overcome the retraining bottleneck, we propose a Meta-Geometric Encoder based on Graph Hypernetworks: unlike standard contrastive learning, which performs only feature-level recognition, our hypernetwork dynamically generates policy parameters from a minimal support set, enabling parameter-level adaptation to complex topologies (e.g., domes, arches) without gradient-based retraining. For structural reasoning, we introduce a Physics-Informed Graph Transformer trained via Soft Actor-Critic (SAC), with a Physics-Bias Attention mechanism that modulates attention scores using contact forces from Discrete Element Model (DEM) simulations, guiding the planner toward structurally critical connections. We further ensure operational efficiency through Kinematics-Aware Sequencing, where the SAC objective penalizes high-energy transitions. Finally, we bridge the Sim2Real gap via Residual Stability Correction, a differentiable optimization layer that fine-tunes coarse assembly actions by minimizing a joint energy-stability cost prior to execution. Experiments show that EUPHORIA significantly reduces energy consumption over decoupled baselines and achieves state-of-the-art success rates on unseen, non-standard geometries with minimal few-shot examples, fusing meta-learning, physics-informed attention, and residual optimization into a cohesive, generalized planner.

Assembling objects from parts requires understanding multimodal instructions, linking them to 3D components, and predicting physically plausible 6-DoF motions for each assembly step. Existing datasets focus on simplified scenarios, overlooking shape complexities and assembly trajectories in industrial assemblies. We introduce AssemblyBench, a synthetic dataset of 2,789 industrial objects with multimodal instruction manuals, corresponding 3D part models, and part assembly trajectories. We also propose a transformer-based model, AssemblyDyno, which uses the instructional manual and the 3D shape of each part to jointly predict assembly order and part assembly trajectories. AssemblyDyno outperforms prior works in both assembly pose estimation and trajectory feasibility, where the latter is evaluated by our physics-based simulations.

Contact-rich assembly is fundamental in robotics but poses significant challenges due to uncertainties in relative poses, such as misalignments and small clearances in peg-in-hole tasks. Existing approaches typically address search and high-precision insertion separately, because these tasks involve distinct action patterns. However, supporting both tasks within a single model, without switching models or weights, is desirable for intelligent assembly systems. In this work, we propose SI-Diff, a framework that learns both search and high-precision insertion through a force-domain diffusion policy. To this end, we introduce a new mode-conditioning mechanism that enables the policy to capture distinct action behaviors under a single framework. Moreover, we develop a new search teacher policy that can generate diverse trajectories. By training on successful and efficient demonstrations provided by the teacher policy, the model learns the mapping from tactile and end-effector velocity observations to effective action behaviors. We conduct thorough experiments to show that SI-Diff extends the tolerance to x-y misalignments from 2 mm to 5 mm compared to the state-of-the-art baseline, TacDiffusion, while also demonstrating strong zero-shot transferability to unseen shapes.

Autonomous robotic assembly of interlocking bricks demands seamless integration of long-horizon task reasoning, spatial grounding, and fine-grained manipulation. This paper presents BrickCraft, a compositional framework designed for long-horizon and generalizable interlocking brick assembly. BrickCraft models the assembly process using a relative formulation, where each step is anchored to a reference brick within the partial structure, thereby decomposing complex tasks into a finite set of reusable primitive skills. BrickCraft bridges the gap between high-level assembly plans and physical execution through situated manuals, which provide explicit spatial guidance for learned visuomotor skills by projecting the assembly intent onto real-time robot observations. Finally, BrickCraft employs a compositional execution pipeline that chains these spatially grounded skills to accomplish long-horizon assembly tasks. Extensive experimental validations demonstrate that BrickCraft acquires proficient assembly skills from a limited set of demonstrations and exhibits strong compositional generalization to unseen structures. The project website is available at https://intelligent-control-lab.github.io/BrickCraft.

Peg-in-hole (PiH) assembly is a fundamental yet challenging robotic manipulation task. While reinforcement learning (RL) has shown promise in tackling such tasks, it requires extensive exploration. In this paper, we propose a novel visual-tactile skill learning framework for the PiH task that leverages its inverse task, i.e., peg-out-of-hole (PooH) disassembly, to facilitate PiH learning. Compared to PiH, PooH is inherently easier as it only needs to overcome existing friction without precise alignment, making data collection more efficient. To this end, we formulate both PooH and PiH as Partially Observable Markov Decision Processes (POMDPs) in a unified environment with shared visual-tactile observation space. A visual-tactile PooH policy is first trained; its trajectories, containing kinematic, visual and tactile information, are temporally reversed and action-randomized to provide expert data for PiH. In the policy learning, visual sensing facilitates the peg-hole approach, while tactile measurements compensate for peg-hole misalignment. Experiments across diverse peg-hole geometries show that the visual-tactile policy attains 6.4% lower contact forces than its single-modality counterparts, and that our framework achieves average success rates of 87.5% on seen objects and 77.1% on unseen objects, outperforming direct RL methods that train PiH policies from scratch by 18.1% in success rate. Demos, code, and datasets are available at https://sites.google.com/view/pooh2pih.

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.

Developing learning-based autonomy for microrobotic manipulation is difficult because physical trials are slow, variable, and poorly suited to large-scale training. We present MicroPush, a lightweight simulation and benchmarking environment for pushing and assembly with magnetic rolling microrobots. The simulator combines overdamped planar dynamics with calibrated rolling actuation, reduced-order contact handling, short-range interaction corrections, and optional background flow, while providing common interfaces for planning, model-based control, reinforcement learning (RL), interactive visualization, and headless evaluation. In no-render tests, MicroPush remains substantially faster than real time, reaching 37.0x real time with 100 passive particles. We further evaluate the simulator through zero-shot sim-to-real policy transfer. A Residual RL-MPC policy is trained entirely in MicroPush, frozen after simulation training, and deployed on the physical system without real-world policy fine-tuning. A 20 μm magnetic microrobot pushes a similarly sized silica particle along a figure-eight trajectory with 1.91 μm median and 4.65 μm 95th-percentile path error, and the same autonomy stack performs sequential line, triangle, and six-particle hexagonal assembly. These results show that a deliberately reduced-order simulator can provide an efficient training and development substrate for sim-to-real microrobotic autonomy.

Human-robot collaborative assembly requires robots to interpret ambiguous corrective instructions while producing physically executable motions. Vision-language models (VLMs) provide semantic reasoning but may select logically inconsistent targets or misjudge execution outcomes. We propose a replanning framework that maps human instructions to Action Target candidates, including grasp poses and tool selections, and combines an Internal Correction Model for pre-execution logical verification with an External Correction Model for post-execution visual verification. The framework integrates VLM reasoning with 6-DoF grasp generation and collision-free trajectory planning. Simulation ablations show configuration-dependent effects: internal correction improves candidate validity, whereas external correction enables recovery for a low-latency VLM but can reduce success when visual verification produces false negatives. Experiments with an upper-body humanoid robot achieved 66.7% success in real-world object fixation, 100% in initial tool selection, and 75.0% in corrective tool selection. These results demonstrate interactive replanning across spatial and semantic collaborative tasks while identifying visual-state verification as a key limitation.