Offline Safe Reinforcement Learning (RL) seeks to address safety constraints by learning from static datasets and restricting exploration. However, these approaches heavily rely on the dataset and struggle to generalize to unseen scenarios safely. In this paper, we aim to improve safety during the deployment of vision-based robotic tasks through online fine-tuning an offline pretrained policy. To facilitate effective fine-tuning, we introduce model-based RL, which is known for its data efficiency. Specifically, our method employs in-sample optimization to improve offline training efficiency while incorporating reachability guidance to ensure safety. After obtaining an offline safe policy, a safe policy expansion approach is leveraged for online fine-tuning. The performance of our method is validated on simulation benchmarks with five vision-only tasks and through real-world robot deployment using limited data. It demonstrates that our approach significantly improves the generalization of offline policies to unseen safety-constrained scenarios. To the best of our knowledge, this is the first work to explore offline-to-online RL for safe generalization tasks. The videos are available at https://sunlighted.github.io/fosp_web/.

Pretraining a policy on offline data followed by fine-tuning through online interactions, known as Offline-to-Online Reinforcement Learning (O2O RL), has emerged as a promising paradigm for real-world RL deployment. However, both offline datasets and online interactions in practical environments are often noisy or even maliciously corrupted, severely degrading the performance of O2O RL. Existing works primarily focus on mitigating the conservatism of offline policies via online exploration, while the robustness of O2O RL under data corruption, including states, actions, rewards, and dynamics, is still unexplored. In this work, we observe that data corruption induces heavy-tailed behavior in the policy, thereby substantially degrading the efficiency of online exploration. To address this issue, we incorporate Inverse Probability Weighted (IPW) into the online exploration policy to alleviate heavy-tailedness, and propose a novel, simple yet effective method termed $\textbf{RPEX}$: $\textbf{R}$obust $\textbf{P}$olicy $\textbf{EX}$pansion. Extensive experimental results on D4RL datasets demonstrate that RPEX achieves SOTA O2O performance across a wide range of data corruption scenarios.