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Visual Sim-to-Real Learning for Robotic Insertion under Geometric Variations: Application to Rebar Installation

arXiv · AI, language, vision and robotics · article · Sep 17, 2026 · UTC

Rebar insertion is among the most repetitive and physically demanding tasks on construction sites, and a contact-rich problem at 1.4 mm clearance. The parts, however, vary at two levels: a nominal design per structural member, and fabrication tolerance around each nominal design. Real-world data therefore has to be re-collected as designs and batches change. We present RebarSim, a visual sim-to-real system trained entirely in simulation. A privileged state-based teacher is trained with reinforcement learning over procedurally generated rebar geometries, then distilled into a multi-view student

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