Humanoid robots get to work

The BMW Group is bringing “Physical AI” to its manufacturing operations with a pilot project featuring humanoid robots set to be launched at its plant in Leipzig, Germany.

The project aims to integrate humanoid robotics into the existing production of cars and to explore further applications in the manufacturing of batteries and components.

It is part of the company’s ambition to advance the digitalisation and use of artificial intelligence in production. A key element in this effort is “Physical AI”, which combines digital artificial intelligence with real machines and robots. 

Milan Nedeljkovic, member of the board of management of BMW AG, production, says: “Digitalisation improves the competitiveness of our production – here in Europe and worldwide. 

“The symbiosis of engineering expertise and artificial intelligence opens up entirely new possibilities in production.” 

The BMW Group last year successfully implemented a pilot project with humanoid robots at its Spartanburg plant in the United States. The insights gained from this project are being leveraged to further develop and scale Physical AI applications.

Part of the development has involved putting isolated data silos into a unified platform in the firm’s production system, meaning all data is consistent, standardised and available at all times. 

This enables digital AI agents to take on increasingly challenging tasks autonomously and in complex environments while continuously learning and becoming available for additional areas of application. 

Michael Nikolaides, senior vice-president production network, supply chain management at BMW Group, adds: “Our aim is to be a technology leader and to integrate new technologies into production at an early stage. 

“Pilot projects help us to test and further develop the use of Physical AI – that is, AI enabled robots capable of learning – under real-world industrial conditions.”

Group says humanoid robots are viewed as a value adding complement to existing automation and they demonstrate potential in monotonous, ergonomically demanding, or safety critical tasks. 

In collaboration with Hexagon, a long standing partner of the BMW Group in the field of sensor technology and software, the first pilot project in Europe is now under way. 

Hexagon Robotics presented its first humanoid robot, Aeon, in June 2025. It had an initial test deployment at BMW Group Plant Leipzig in December 2025, a further on is planned from April to ensure full integration for the pilot phase starting in the middle of this year.

During testing and in the pilot phase, the robot will be used in the assembly of high voltage batteries and in component manufacturing.

Precision work

The first deployment of humanoid robots at a BMW Group plant took place at the Spartanburg plant in 2025, in collaboration with the technology company Figure AI. 

The results demonstrated Physical AI can deliver added value under real-world conditions. Within 10 months, the robot Figure 02 supported the production of more than 30,000 BMW X3, working 10-hour shifts daily from Monday to Friday. 

Figure 02 handled the removal and positioning of sheet metal parts for the welding process – a task that is demanding in terms of speed and accuracy while also being physically exhausting. 

In total, it moved more than 90,000 components and covered approximately 1.2 million steps in about 1,250 operating hours.

BMW Group says the pilot confirmed humanoid robots can safely perform precise, repetitive work steps – such as positioning components with millimetre precision – and provided important insights for the further deployment of Physical AI in production.