BMW - Aeon_the-humanoid-robot-a
The BMW Group is accelerating the integration of artificial intelligence into its manufacturing network – and is now taking a decisive next step in Europe. For the first time, the company is deploying humanoid robots in series production in Germany, launching a pilot project at its Leipzig plant.
The initiative centres on what BMW calls “Physical AI” – the fusion of digital artificial intelligence with real-world machines and robots. The aim: to integrate AI-enabled humanoid systems into existing automotive production, while exploring additional applications in battery and component manufacturing.
“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.
Artificial intelligence is already deeply embedded in BMW’s production system – from digital twins in the virtual factory to AI-driven quality control and autonomous intralogistics. A key enabler is a unified IT and data model that replaces isolated data silos with a standardised, company-wide data platform.
This consistent data backbone allows AI agents to operate autonomously in complex environments and continuously improve through learning. Combined with robotics, these agents form the basis of Physical AI – a development BMW describes as a paradigm shift in manufacturing.
“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.
“The successful first deployment of humanoid robots at our BMW Group plant in Spartanburg in the USA proves that a humanoid robot can function not only under controlled laboratory conditions but also in an existing automotive manufacturing environment.”
The European pilot project is being carried out in collaboration with Hexagon Robotics, a Zurich-based unit of Hexagon specialising in Physical AI. Its humanoid robot AEON, unveiled in 2025, is now undergoing step-by-step integration at BMW Group Plant Leipzig.
“We are delighted to deploy a humanoid robot for the first time in a pilot project at a plant in Germany,” said Michael Ströbel, Head of Process Management and Digitalisation, Order to Delivery at BMW Group.
“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.”
AEON’s human-like design allows flexible attachment of different grippers and scanning tools, enabling it to handle tasks in high-voltage battery assembly and component manufacturing. Humanoid robotics is positioned as a complement to existing automation, particularly suited to monotonous, ergonomically demanding or safety-critical tasks – with the goal of relieving employees and improving working conditions.
“We are very pleased to be working with the BMW Group to advance the use of humanoid robots in real-world environments,” said Arnaud Robert, President of Hexagon Robotics.
BMW’s move into Germany builds on experience gained in the United States. In 2025, the company deployed humanoid robots for the first time at its Spartanburg plant in collaboration with Figure AI.
Within ten months, the robot supported the production of more than 30,000 BMW X3 vehicles, working ten-hour shifts and handling the precise removal and positioning of sheet metal parts for welding. The pilot demonstrated that humanoid robots can reliably perform repetitive, millimetre-precise tasks in a live automotive environment.
One key insight: the transition from laboratory testing to real production was faster than expected, thanks to integration via standardised interfaces within BMW’s Smart Robotics ecosystem.
To coordinate future projects, BMW has established a new “Center of Competence for Physical AI in Production,” consolidating expertise in AI and robotics across the organisation. Technology partners are evaluated according to defined industrialisation criteria and tested first in laboratory environments before moving to pilot deployments in plants.
“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,” said Felix Haeckel, Team Lead CoC Physical AI for Production.
With Leipzig now joining Spartanburg, the BMW Group is positioning itself at the forefront of humanoid robotics in automotive manufacturing. The coming months will determine how quickly Physical AI moves from pilot status into broader industrial reality – but the direction is clear: AI is no longer confined to software and simulation; it is stepping onto the shop floor.
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