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David Howard

Publications and source records attributed to David Howard.

At least 19 recordsLinked to original sources
arXiv2026

SimTO-Robust: Automated Design of Soft Grippers Robust to Grasp Pose and Object Geometry

Robotic grippers operating in unstructured environments must robustly grasp objects of different shapes and sizes despite perception and positioning errors. Soft grippers that can achieve this robustness through intelligent mechanical design rather than sophisticated control software offer a promising solution. However, no existing computational design framework explicitly optimises soft gripper morphology for robustness across object geometries and grasp poses. We introduce SimTO-Robust, a generalisation of simulation-driven topology optimisation (SimTO) that simulates grasps across multiple objects and poses and aggregates their contact forces to guide gripper morphology optimisation. We generate 6,646 designs and physically evaluate 24 of them alongside 10 specialised SimTO designs, two rigid baseline grippers, and a baseline generalist soft gripper produced using conventional topology optimisation. All 37 grippers are tested in a pick-and-place task involving five feature-rich objects and six grasp poses, with external disturbances of increasing magnitude applied during the task. On average, SimTO-Robust designs complete pick-and-place more reliably than specialised SimTO designs and the rigid baselines. The best SimTO-Robust designs also withstood more of the applied disturbances than any other tested gripper. These results show that incorporating diverse grasp conditions into simulation-driven topology optimisation is a simple and effective approach to improving real-world soft gripper robustness. More broadly, they show that robust robotic grasping can be achieved through intelligent mechanical design rather than sophisticated sensing and control.

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arXiv2026

Adaptive Bendpoint Formation in Octopus-Inspired Soft Continuum Arms

Octopuses exhibit a powerful form of embodied intelligence from a highly adaptable soft body. One key mechanism is the ability to instantiate bending points at any location along the arm, which enables performant and dexterous behaviours. Taking inspiration from the octopus for its dexterity, this study focuses on changing the curvature of a tendon-actuated arm by adaptively changing the anchoring end-point along the arm. An array of inflatable shells is integrated into the arm, where inflating a shell causes an increase in friction at the location, jamming the tendon and creating a temporary new anchoring point. The novel soft actuator does not break the continuity of the arm between the actuated segment and the loose segment. Experiments show that the actuated segment has a non-constant bell-shaped curvature which is comparable to that of a real octopus arm during a reaching motion. Compared to conventional single-tendon continuum manipulators, the proposed design offers an expanded workspace and enhanced dexterity through the ability to independently shape different regions of the arm through selective curvature tuning. At the same time, it avoids the mechanical complexity typically associated with multi-segment, multi-actuator systems.

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arXiv2026

Graph-Based Design of Soft Grippers with Multi-Objective Quality-Diversity Optimisation

Effective manipulation across diverse objects is critical for applications ranging from agricultural harvesting to laboratory and domestic automation. While the inherent compliance of soft robotics is well suited to this challenge, designing grippers that generalize across tasks remains difficult due to the vast design space of continuum mechanics and the risk of overfitting to specific scenarios. We propose a graph-based design space for representing soft structures and mechanisms, coupled with a multi-objective, diversity-driven genetic optimization framework that explicitly promotes solution variety throughout the design process. Using multiple grasping scenarios during optimization, we study how task diversity influences the emergence of generalization to unseen objects and contact conditions. Our results show that optimization over a sufficiently diverse set of grasping cases leads to designs with emergent generalization, exhibiting improved robustness compared to task-specific solutions on novel scenarios. These findings suggest that diversity-driven optimization offers a principled pathway toward general-purpose soft grippers, aligned with the adaptable nature of soft robotics.

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arXiv2026

RAPT: Model-Predictive Out-of-Distribution Detection and Failure Diagnosis for Sim-to-Real Humanoid Deployment

Deploying learned control policies is risky because policies that appear robust in simulation can confidently enter out-of-distribution (OOD) states after Sim-to-Real transfer, causing silent failures and potential hardware damage. Existing anomaly detectors often fail to meet the requirements of high-rate control, extremely low false-positive rates, and interpretable failure feedback. We present \textbf{RAPT} (Recurrent Anomaly Probabilistic Trajectory Model), a lightweight, self-supervised $50$\,Hz deployment monitor that learns nominal execution from large-scale simulation and produces calibrated, per-dimension predictive-deviation signals online. RAPT enables OOD detection under strict false-positive constraints while localizing \emph{when and where} real execution departs from nominal behavior. For post-hoc diagnosis, RAPT combines temporal saliency, joint-kinematic summaries, and LLM-based semantic reasoning to classify likely failure causes in a zero-shot setting. In simulation across four Isaac Lab tasks, RAPT improves TPR by $37\%$ over the strongest baseline at $0.5\%$ episode-level FPR; on hardware, it achieves $89\%$ TPR across $78$ trials with fewer false positives than high-frequency-compatible baselines, and reaches $75\%$ semantic failure diagnosis accuracy across $21$ categories on a challenging OOD subset. Project website, code, and videos: https://humphreymunn.github.io/RAPT/.

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arXiv2026

Soft Pneumatic Grippers: Topology optimization, 3D-printing and Experimental validation

Typically, heuristic/trial-based approaches are used to design soft pneumatic grippers (SPGs). This paper presents a systematic topology optimization framework for developing SPGs. The design-dependent nature of actuating load is modeled using Darcy's law with an added drainage term. A 2D soft arm unit is then optimized as a compliant mechanism under pneumatic loading. To ensure the design is robust and manufacturable, the problem is formulated as a min-max optimization, where output deformations of blueprint and eroded designs are considered. A volume constraint is imposed on the blueprint part, while a strain-energy constraint is enforced on the eroded part. The Method of Moving Asymptotes is employed to solve optimization problems. The optimized 2D part is extruded suitably to generate a 3D unit. Ten such 3D units are assembled to create a gripper arm. Both the optimized 2D unit and the corresponding gripper arm outperform their conventional rectangular designs under pneumatic loading, demonstrating the efficacy of the proposed approach. The arms are fabricated using the SLA printing technique. Numerical and experimental results are compared at different pneumatic loads. Four 3D-printed arms are integrated with a supporting structure to form the SPG. The gripping action of the SPG is demonstrated on objects with different weights, sizes, structures, stiffnesses, and shapes.

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arXiv2026

SimTO: A two-stage, simulation-driven topology optimization framework for bespoke soft robotic grippers

Soft robotic grippers are essential for grasping delicate, geometrically complex objects in manufacturing, healthcare and agriculture. However, existing designs struggle to grasp feature-rich objects with high topological variability, including gears with sharp tooth profiles on automotive assembly lines, corals with fragile protrusions, or vegetables with irregular branching structures like broccoli. Unlike simple geometric primitives such as cubes or spheres, feature-rich objects lack a clear "optimal" contact surface, making them both difficult to grasp and susceptible to damage. Safe handling of such objects therefore requires specialized soft grippers whose morphology is tailored to the object's features. Topology optimization offers a promising approach for producing specialized grippers, but its utility is limited by the need for pre-defined load cases. For soft grippers, these loads arise from hundreds of unpredictable gripper-object contact forces during grasping and are unknown a priori. To address this problem, we introduce SimTO, a two-stage, simulation-driven topology optimization framework that automatically extracts load cases from a dynamic, contact-rich grasping simulation before performing classical topology optimization, eliminating the need for manual load specification. Given an arbitrary feature-rich object, SimTO produces highly customized soft grippers with fine-grained morphological features tailored to the object geometry. Physical experiments confirm that our specialized grippers achieve higher grasp forces than a generalist design produced by conventional topology optimization methods, while numerical experiments show that they achieve high grasp success rates across varying object poses and strong generalization to a set of unseen objects.

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arXiv2026

An Experimental Characterization of Mechanical Layer Jamming Systems

Organisms in nature, such as Cephalopods and Pachyderms, exploit stiffness modulation to achieve amazing dexterity in the control of their appendages. In this paper, we explore the phenomenon of layer jamming, which is a popular stiffness modulation mechanism that provides an equivalent capability for soft robots. More specifically, we focus on mechanical layer jamming, which we realise through two-layer multi material structure with tooth-like protrusions. We identify key design parameters for mechanical layer jamming systems, including the ability to modulate stiffness, and perform a variety of comprehensive tests placing the specimens under bending and torsional loads to understand the influence of our selected design parameters (mainly tooth geometry) on the performance of the jammed structures. We note the ability of these structures to produce a peak change in stiffness of 5 times in bending and 3.2 times in torsion. We also measure the force required to separate the two jammed layers, an often ignored parameter in the study of jamming-induced stiffness change. This study aims to shed light on the principled design of mechanical layer jammed systems and guide researchers in the selection of appropriate designs for their specific application domains.

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arXiv2026

Generalized Task-Driven Design of Soft Robots via Reduced-Order FEM-based Surrogate Modeling

Task-driven design of soft robots requires models that are physically accurate and computationally efficient, while remaining transferable across actuator designs and task scenarios. However, existing modeling approaches typically face a fundamental trade-off between physical fidelity and computational efficiency, which limits model reuse across design and task variations and constrains scalable task-driven optimization. This paper presents a unified reduced-order finite element method (FEM)-based surrogate modeling pipeline for generalized task-driven soft robot design. High-fidelity FEM simulations characterize actuator behavior at the modular level, from which compact surrogate joint models are constructed for evaluation within a pseudo-rigid body model (PRBM). A meta-model maps actuator design parameters to surrogate representations, enabling rapid instantiation across a parameterized actuator family. The resulting models are embedded into a PRBM-based simulation environment, supporting task-level simulation and optimization under realistic physical constraints. The proposed pipeline is validated through sim-to-real transfer across multiple actuator types, including bellow-type pneumatic actuators and a tendon-driven soft finger, as well as two task-driven design studies: soft gripper co-design via Reinforcement Learning (RL) and 3D actuator shape matching via evolutionary optimization. The results demonstrate high accuracy, efficiency, and reliable reuse, providing a scalable foundation for autonomous task-driven soft robot design.

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arXiv2026

HRI-SA: A Multimodal Dataset for Online Assessment of Human Situational Awareness during Remote Human-Robot Teaming

Maintaining situational awareness (SA) is critical in human-robot teams. Yet, under high workload and dynamic conditions, operators often experience SA gaps. Automated detection of SA gaps could provide timely assistance for operators. However, conventional SA measures either disrupt task flow or cannot capture real-time fluctuations, limiting their operational utility. To the best of our knowledge, no publicly available dataset currently supports the systematic evaluation of online human SA assessment in human-robot teaming. To advance the development of online SA assessment tools, we introduce HRI-SA, a multimodal dataset from 30 participants in a realistic search-and-rescue human-robot teaming context, incorporating eye movements, pupil diameter, biosignals, user interactions, and robot data. The experimental protocol included predefined events requiring timely operator assistance, with ground truth SA latency of two types (perceptual and comprehension) systematically obtained by measuring the time between assistance need onset and resolution. We illustrate the utility of this dataset by evaluating standard machine learning models for detecting perceptual SA latencies using generic eye-tracking features and contextual features. Results show that eye-tracking features alone effectively classified perceptual SA latency (recall=88.91%, F1=67.63%) using leave-one-group-out cross-validation, with performance improved through contextual data fusion (recall=91.51%, F1=80.38%). This paper contributes the first public dataset supporting the systematic evaluation of SA throughout a human-robot teaming mission, while also demonstrating the potential of generic eye-tracking features for continuous perceptual SA latency detection in remote human-robot teaming.

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arXiv2026

Grasp Synthesis Matching From Rigid To Soft Robot Grippers Using Conditional Flow Matching

A representation gap exists between grasp synthesis for rigid and soft grippers. Anygrasp [1] and many other grasp synthesis methods are designed for rigid parallel grippers, and adapting them to soft grippers often fails to capture their unique compliant behaviors, resulting in data-intensive and inaccurate models. To bridge this gap, this paper proposes a novel framework to map grasp poses from a rigid gripper model to a soft Fin-ray gripper. We utilize Conditional Flow Matching (CFM), a generative model, to learn this complex transformation. Our methodology includes a data collection pipeline to generate paired rigid-soft grasp poses. A U-Net autoencoder conditions the CFM model on the object's geometry from a depth image, allowing it to learn a continuous mapping from an initial Anygrasp pose to a stable Fin-ray gripper pose. We validate our approach on a 7-DOF robot, demonstrating that our CFM-generated poses achieve a higher overall success rate for seen and unseen objects (34% and 46% respectively) compared to the baseline rigid poses (6% and 25% respectively) when executed by the soft gripper. The model shows significant improvements, particularly for cylindrical (50% and 100% success for seen and unseen objects) and spherical objects (25% and 31% success for seen and unseen objects), and successfully generalizes to unseen objects. This work presents CFM as a data-efficient and effective method for transferring grasp strategies, offering a scalable methodology for other soft robotic systems.

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arXiv2026

ReefFlex: A Generative Design Framework for Soft Robotic Grasping of Organic and Fragile objects

Climate change, invasive species and human activities are currently damaging the world's coral reefs at unprecedented rates, threatening their vast biodiversity and fisheries, and reducing coastal protection. Solving this vast challenge requires scalable coral regeneration technologies that can breed climate-resilient species and accelerate the natural regrowth processes; actions that are impeded by the absence of safe and robust tools to handle the fragile coral. We investigate ReefFlex, a generative soft finger design methodology that explores a diverse space of soft fingers to produce a set of candidates capable of safely grasping fragile and geometrically heterogeneous coral in a cluttered environment. Our key insight is encoding heterogeneous grasping into a reduced set of motion primitives, creating a simplified, tractable multi-objective optimisation problem. To evaluate the method, we design a soft robot for reef rehabilitation, which grows and manipulates coral in onshore aquaculture facilities for future reef out-planting. We demonstrate ReefFlex increases both grasp success and grasp quality (disturbance resistance, positioning accuracy) and reduces in adverse events encountered during coral manipulation compared to reference designs. ReefFlex, offers a generalisable method to design soft end-effectors for complex handling and paves a pathway towards automation in previously unachievable domains like coral handling for restoration.

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arXiv2025

Programmable Telescopic Soft Pneumatic Actuators for Deployable and Shape Morphing Soft Robots

Soft Robotics presents a rich canvas for free-form and continuum devices capable of exerting forces in any direction and transforming between arbitrary configurations. However, there is no current way to tractably and directly exploit the design freedom due to the curse of dimensionality. Parameterisable sets of designs offer a pathway towards tractable, modular soft robotics that appropriately harness the behavioural freeform of soft structures to create rich embodied behaviours. In this work, we present a parametrised class of soft actuators, Programmable Telescopic Soft Pneumatic Actuators (PTSPAs). PTSPAs expand axially on inflation for deployable structures and manipulation in challenging confined spaces. We introduce a parametric geometry generator to customise actuator models from high-level inputs, and explore the new design space through semi-automated experimentation and systematic exploration of key parameters. Using it we characterise the actuators' extension/bending, expansion, and stiffness and reveal clear relationships between key design parameters and performance. Finally we demonstrate the application of the actuators in a deployable soft quadruped whose legs deploy to walk, enabling automatic adaptation to confined spaces. PTSPAs present new design paradigm for deployable and shape morphing structures and wherever large length changes are required.

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arXiv2025

3D Printable Soft Liquid Metal Sensors for Delicate Manipulation Tasks

Robotics and automation are key enablers to increase throughput in ongoing conservation efforts across various threatened ecosystems. Cataloguing, digitisation, husbandry, and similar activities require the ability to interact with delicate, fragile samples without damaging them. Additionally, learning-based solutions to these tasks require the ability to safely acquire data to train manipulation policies through, e.g., reinforcement learning. To address these twin needs, we introduce a novel method to print free-form, highly sensorised soft 'physical twins'. We present an automated design workflow to create complex and customisable 3D soft sensing structures on demand from 3D scans or models. Compared to the state of the art, our soft liquid metal sensors faithfully recreate complex natural geometries and display excellent sensing properties suitable for validating performance in delicate manipulation tasks. We demonstrate the application of our physical twins as 'sensing corals': high-fidelity, 3D printed replicas of scanned corals that eliminate the need for live coral experimentation, whilst increasing data quality, offering an ethical and scalable pathway for advancing autonomous coral handling and soft manipulation broadly. Through extensive bench-top manipulation and underwater grasping experiments, we show that our sensing coral is able to detect grasps under 0.5 N, effectively capturing the delicate interactions and light contact forces required for coral handling. Finally, we showcase the value of our physical twins across two demonstrations: (i) automated coral labelling for lab identification and (ii) robotic coral aquaculture. Sensing physical twins such as ours can provide richer grasping feedback than conventional sensors providing experimental validation of prior to deployment in handling fragile and delicate items.

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arXiv2025

Scalable Multi-Objective Robot Reinforcement Learning through Gradient Conflict Resolution

Reinforcement Learning (RL) robot controllers usually aggregate many task objectives into one scalar reward. While large-scale proximal policy optimisation (PPO) has enabled impressive results such as robust robot locomotion in the real world, many tasks still require careful reward tuning and are brittle to local optima. Tuning cost and sub-optimality grow with the number of objectives, limiting scalability. Modelling reward vectors and their trade-offs can address these issues; however, multi-objective methods remain underused in RL for robotics because of computational cost and optimisation difficulty. In this work, we investigate the conflict between gradient contributions for each objective that emerge from scalarising the task objectives. In particular, we explicitly address the conflict between task-based rewards and terms that regularise the policy towards realistic behaviour. We propose GCR-PPO, a modification to actor-critic optimisation that decomposes the actor update into objective-wise gradients using a multi-headed critic and resolves conflicts based on the objective priority. Our methodology, GCR-PPO, is evaluated on the well-known IsaacLab manipulation and locomotion benchmarks and additional multi-objective modifications on two related tasks. We show superior scalability compared to parallel PPO (p = 0.04), without significant computational overhead. We also show higher performance with more conflicting tasks. GCR-PPO improves on large-scale PPO with an average improvement of 9.5%, with high-conflict tasks observing a greater improvement. The code is available at https://github.com/humphreymunn/GCR-PPO.

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arXiv2025

Whole-Body Dynamic Throwing with Legged Manipulators

Throwing with a legged robot involves precise coordination of object manipulation and locomotion - crucial for advanced real-world interactions. Most research focuses on either manipulation or locomotion, with minimal exploration of tasks requiring both. This work investigates leveraging all available motors (full-body) over arm-only throwing in legged manipulators. We frame the task as a deep reinforcement learning (RL) objective, optimising throwing accuracy towards any user-commanded target destination and the robot's stability. Evaluations on a humanoid and an armed quadruped in simulation show that full-body throwing improves range, accuracy, and stability by exploiting body momentum, counter-balancing, and full-body dynamics. We introduce an optimised adaptive curriculum to balance throwing accuracy and stability, along with a tailored RL environment setup for efficient learning in sparse-reward conditions. Unlike prior work, our approach generalises to targets in 3D space. We transfer our learned controllers from simulation to a real humanoid platform.

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arXiv2025

Bayesian Adaptive Calibration and Optimal Design

The process of calibrating computer models of natural phenomena is essential for applications in the physical sciences, where plenty of domain knowledge can be embedded into simulations and then calibrated against real observations. Current machine learning approaches, however, mostly rely on rerunning simulations over a fixed set of designs available in the observed data, potentially neglecting informative correlations across the design space and requiring a large amount of simulations. Instead, we consider the calibration process from the perspective of Bayesian adaptive experimental design and propose a data-efficient algorithm to run maximally informative simulations within a batch-sequential process. At each round, the algorithm jointly estimates the parameters of the posterior distribution and optimal designs by maximising a variational lower bound of the expected information gain. The simulator is modelled as a sample from a Gaussian process, which allows us to correlate simulations and observed data with the unknown calibration parameters. We show the benefits of our method when compared to related approaches across synthetic and real-data problems.

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arXiv2025

A Framework for Dynamic Situational Awareness in Human Robot Teams: An Interview Study

In human-robot teams, human situational awareness is the operator's conscious knowledge of the team's states, actions, plans and their environment. Appropriate human situational awareness is critical to successful human-robot collaboration. In human-robot teaming, it is often assumed that the best and required level of situational awareness is knowing everything at all times. This view is problematic, because what a human needs to know for optimal team performance varies given the dynamic environmental conditions, task context and roles and capabilities of team members. We explore this topic by interviewing 16 participants with active and repeated experience in diverse human-robot teaming applications. Based on analysis of these interviews, we derive a framework explaining the dynamic nature of required situational awareness in human-robot teaming. In addition, we identify a range of factors affecting the dynamic nature of required and actual levels of situational awareness (i.e., dynamic situational awareness), types of situational awareness inefficiencies resulting from gaps between actual and required situational awareness, and their main consequences. We also reveal various strategies, initiated by humans and robots, that assist in maintaining the required situational awareness. Our findings inform the implementation of accurate estimates of dynamic situational awareness and the design of user-adaptive human-robot interfaces. Therefore, this work contributes to the future design of more collaborative and effective human-robot teams.

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arXiv2024

SoGraB: A Visual Method for Soft Grasping Benchmarking and Evaluation

Recent years have seen soft robotic grippers gain increasing attention due to their ability to robustly grasp soft and fragile objects. However, a commonly available standardised evaluation protocol has not yet been developed to assess the performance of varying soft robotic gripper designs. This work introduces a novel protocol, the Soft Grasping Benchmarking and Evaluation (SoGraB) method, to evaluate grasping quality, which quantifies object deformation by using the Density-Aware Chamfer Distance (DCD) between point clouds of soft objects before and after grasping. We validated our protocol in extensive experiments, which involved ranking three Fin-Ray gripper designs with a subset of the EGAD object dataset. The protocol appropriately ranked grippers based on object deformation information, validating the method's ability to select soft grippers for complex grasping tasks and benchmark them for comparison against future designs.

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