BMW Group to deploy humanoid robots in production in Germany for the first time
Source: Hacker News
Munich. The BMW Group is consistently advancing the digitalisation and use of artificial intelligence in production. A key element in this effort is Physical AI, which combines digital artificial intelligence (AI) with real machines and robots. This enables intelligent systems such as humanoid robots to be integrated into real‑world production processes.
For the first time, the BMW Group is now bringing Physical AI to Europe and launching a pilot project with humanoid robots at the Leipzig plant. The project aims to integrate humanoid robotics into existing series production of cars and to explore further applications in the production of batteries and components.
“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,” said Milan Nedeljković, Member of the Board of Management of BMW AG, Production.
Last year, the BMW Group 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.
Unified IT and data model in the production system
Artificial intelligence is already an integral part of the BMW Group’s production system. From the virtual factory with digital twins and AI‑enabled quality controls to intralogistics with autonomous transport solutions, intelligent systems are used in almost all production steps.
A prerequisite for the effective use of artificial intelligence in production is a unified IT and data model across the entire production system. The BMW Group has consistently transformed isolated data silos into a unified data platform, meaning that all data is:
- consistent
- standardised
- 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. The introduction of intelligent and autonomous decision‑making agents marks a paradigm shift in production. In combination with robots, these digital AI agents are what make up Physical AI.
“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,” said Michael Nikolaides, Senior Vice President Production Network, Supply Chain Management at BMW Group.
Digitalisation and artificial intelligence are core elements of BMW iFACTORY and are the foundation for future‑proof, flexible, and competitive production.
Humanoid robotics complements existing automation
The BMW Group is strategically expanding its automation portfolio to include Physical AI and humanoid robotics. Humanoid robots are viewed as a value‑adding complement to existing automation, especially for:
- monotonous tasks
- ergonomically demanding tasks
- safety‑critical tasks
The goal is to relieve employees and further improve working conditions.
Center of Competence for Physical AI in Production consolidates expertise
Its consistent data platform in production makes the BMW Group an attractive partner for technology companies seeking to test the possibilities of Physical AI – particularly humanoid robotics – in an industrial environment under real‑world conditions. By setting up the new Center of Competence for Physical AI in Production, the BMW Group is taking the next step in consolidating its expertise and ensuring that the full range of knowledge can be leveraged across the organisation.
The BMW Group follows a clearly structured approach:
- Evaluation – Technology partners are assessed against defined maturity and industrialisation criteria.
- Laboratory testing – Partners are evaluated on‑site using real use cases from the BMW production system to test integration capability.
- Initial test deployment – Successful laboratory tests lead to a pilot deployment under real‑world production conditions at a BMW Group plant.
- Full pilot phase – After a successful initial deployment, the actual pilot phase is launched.
First pilot project with humanoid robots in Europe
In collaboration with Hexagon, a long‑standing partner of the BMW Group in sensor technology and software, the first European pilot project is now underway. Hexagon’s Zürich unit, Hexagon Robotics, specialises in Physical AI and presented its first humanoid robot, AEON, in June 2025.
- Theoretical evaluation & laboratory tests – Completed successfully.
- Initial test deployment – Conducted at BMW Group Plant Leipzig in December 2025.
- Further test deployment – Planned from April 2026 to ensure full integration for the actual pilot phase starting in summer 2026.
The Leipzig deployment focuses on a multifunctional application of the robot. AEON’s human‑like body allows a wide range of hand and gripper elements or scanning tools to be flexibly attached and enables dynamic use on wheels. During testing and later in the pilot phase, the robot will be used in:
- assembly of high‑voltage batteries
- component manufacturing
Successful pilot at BMW Group Plant Spartanburg provides key insights for use of humanoid robots in production
The world’s first deployment of humanoid robots at a BMW Group plant took place at the Spartanburg plant in the United States in 2025, in collaboration with the technology company Figure AI. The results demonstrated… (text continues)
Physical AI Demonstrates Measurable Value in Real‑World Production
Physical AI proved its worth under real‑world conditions. Within ten months, the robot Figure 02 supported the production of more than 30,000 BMW X3 vehicles, working ten‑hour shifts daily from Monday to Friday. Figure 02 handled the precise removal and positioning of sheet‑metal parts for the welding process – a task that is especially demanding in terms of speed, accuracy, and physical effort.
- Components moved: > 90,000
- Steps performed: ≈ 1.2 million
- Operating time: ≈ 1,250 hours
The pilot confirmed that humanoid robots can safely perform precise, repetitive work steps (e.g., positioning components with millimetre precision) and provided valuable insights for further deployment of Physical AI in production.
Early‑Stage Integration
During the initial test phases with Figure 02, it was essential to involve all relevant areas at an early stage:
- Production IT infrastructure
- Occupational safety
- Production process management
- Shop‑floor logistics
Key finding: The transition from laboratory to the actual production environment was faster than expected. Motion sequences trained in the lab could be quickly transferred into stable shift operation. To ensure smooth coexistence with existing systems, integration into the BMW Smart Robotics ecosystem was implemented via standardized interfaces.
Test Phase in the Body Shop (Spartanburg)
The body shop in Spartanburg was deliberately selected because it already has a high degree of automation. BMW Group employees in this area have extensive experience integrating new technologies and processes. For example, material supply on the line is already carried out almost exclusively via automated Smart Transport Robots (STR).
- Early communication from the project team ensured transparency from the outset and promoted acceptance.
- Deployment of humanoid robots generated great interest among employees and quickly became a natural part of everyday work.
Future Evaluation
The BMW Group and Figure are currently evaluating additional use cases for deploying the Figure 03 robot.
Additional Quotes for Use
Michael Nikolaides – Senior Vice President Production Network, Supply Chain Management, BMW Group
“Our aim is to be a technology leader and to integrate new technologies into production at an early stage. Pilot projects help us test and further develop the use of Physical AI – that is, AI‑enabled robots capable of learning – under real‑world industrial conditions. The successful first deployment of humanoid robots at our BMW Group plant in Spartanburg, USA, proves that a humanoid robot can function not only under controlled laboratory conditions but also in an existing automotive manufacturing environment.”
Michael Ströbel – Head of Process Management and Digitalisation, Order to Delivery, BMW Group
“We are delighted to deploy a humanoid robot for the first time in a pilot project at a plant in Germany. Following evaluation by our Center of Competence for Physical AI in Production, tests were carried out in the laboratory and at Plant Leipzig at the end of last year. This year, our focus is on step‑by‑step integration into our production system to explore a wide range of applications. The emphasis is on researching multifunctional use of the robot in various production areas such as battery manufacturing for energy modules and component production for exterior parts. With Hexagon, we have found a proven long‑standing partner with a highly innovative approach to humanoid robotics for this project.”
Felix Haeckel – Team Lead CoC Physical AI for Production
“At our new Center of Competence for Physical AI in Production, we are pooling our expertise to make knowledge on AI and robotics widely usable within the company. In recent years, we have built up an international team of experts that, in addition to in‑house research and programming, is dedicated to the gradual integration of AI into the existing production system. At the same time, our team in Munich is driving its own robotics research to set up, support, and further develop pilot projects in the field of Physical AI at our plants.”
Arnaud Robert – President of Hexagon Robotics
“We are very pleased to be working with the BMW Group to advance the use of humanoid robots in real‑world environments.”