How AI-powered humanoid robots are changing auto manufacturing at BMW, Tesla, and Mercedes-Benz

The robots are coming. And they are starting to look, move and work a lot the way that we do. 

Automotive production is witnessing a critical shift in production environments, driven by the rise of humanoid robots, and the possibilities offered by artificial intelligence (AI) integration. Once confined to industrial robots performing highly specific, repetitive tasks, car manufacturing is now entering an era where machines with human-like dexterity, cognitive learning, and autonomous decision-making capabilities are being deployed on the factory floor. 

One of the most striking developments in this space is BMW’s adoption of humanoid robots in collaboration with Figure AI. The Munich-based manufacturer is testing these robots in real-world production settings to enhance flexibility, address labour shortages, and automate tasks that were previously considered beyond the capabilities of traditional automation. And very quickly, automotive production expects these humanoids to be an integral part of their manufacturing processes. 

BMW’s production board member Milan Nedeljković commented on the incoming shift, saying, “the developments in the field of robotics are promising. With early testing, we are now exploring the possible uses of humanoid robots in production. 

“We want to accompany this technology from development to industrialisation.”  

Humanoid robots: A leap forward in automotive production 

‘Classical’ industrial robots have been a mainstay in automotive production for decades, performing tasks such as welding, painting, and assembly with speed and precision. However, these robots have traditionally been limited in their scope, requiring pre-programmed instructions and operating in highly structured environments. The latest generation of humanoid robots—equipped with advanced AI, computer vision, and sophisticated actuators—marks a fundamental departure from this paradigm. 

Unlike their industrial predecessors, humanoid robots are designed to interact more naturally with human workers, adapt to unstructured environments, and perform a wide range of tasks without the need for extensive programming - way beyond the capabilities of present collaborative robots (cobots). These humanoids are expected to bridge the automation gaps that traditional systems could not address, such as handling complex assembly processes, collaborating with human operators, and even learning tasks on the go. 

Carolin Richter, head of next-generation robotics at BMW, underscored this transformation at the Automotive Logistics and Digital Strategies Europe event in December: “Generative AI offers us the potential to tackle tasks previously considered impossible to automate.” 

BMW’s humanoid robot trials with Figure AI 

BMW is among the first major automakers to trial humanoid robots in active production settings. The company’s collaboration with Figure AI—a Silicon Valley-based robotics firm—has led to successful deployments of the Figure 02, the second iteration of a humanoid robot at its Spartanburg plant in South Carolina.  

These humanoids have been integrated into BMW’s “iFactory” initiative, a digital-first production strategy aimed at enhancing efficiency, sustainability, and flexibility in manufacturing. In these trials, humanoid robots have demonstrated their ability to insert sheet metal parts into fixtures, a task that requires precision, dexterity, and real-time environmental awareness.  

According to BMW, the robots have shown the capability to handle components with millimetre accuracy, something that traditional robotic arms struggle within highly dynamic production environments. 

BMW’s adoption of humanoid robots aligns with its broader strategy to address workforce shortages and increase production agility. As Richter explains: “We envision a future where robots can be trained without programming—a future where tasks are taught through voice commands or imitation learning.” 

Richter also highlighted that humanoids do not necessarily need a bipedal design for industrial use, as “we actually don’t need a bipedal robot to be… upper body functions, arms and hands are very interesting.” She suggested that a robot on a mobile platform might be more practical for industrial environments due to ease of certification, better battery life, and increased strength. BMW is also working on a “smart robotics platform” that will integrate humanoid robots into existing production systems, ensuring flexibility and avoiding reliance on a single supplier.  

This vision represents a significant departure from conventional robotic automation, where machines must be meticulously programmed for every new task. Instead, humanoid robots equipped with generative AI can learn through observation, voice guidance, or direct human interaction, making them far more versatile than their predecessors. 

The Role of AI in humanoid robotics 

The rapid advancement of AI is the driving force behind the rise of humanoid robots in automotive production. Unlike traditional industrial robots, which rely on rigid programming and fixed algorithms, AI-powered humanoid robots leverage machine learning, natural language processing, and generative AI to enhance their adaptability and decision-making capabilities. 

Generative AI plays a crucial role in enabling robots to interpret complex tasks, recognise patterns, and learn from human operators. It allows robots to process vast amounts of data in real time, make predictive decisions, and adjust their actions dynamically based on environmental feedback. As Richter aptly puts it: 

“With generative AI, we are bridging the gaps that traditional automation struggled to address.” 

This AI-driven approach is particularly relevant in automotive assembly lines, where tasks can vary significantly based on vehicle models, customer specifications, and production volumes. Humanoid robots can be trained to perform different functions on the same production line, reducing downtime and enhancing operational efficiency. 

Challenges and considerations in deploying humanoid robots 

While humanoid robots hold significant promise, their adoption in automotive manufacturing comes with several challenges: 

• Cost and ROI: The development and deployment of humanoid robots involve substantial investment. Automakers must assess the long-term return on investment (ROI) and ensure that the benefits outweigh the costs. 

• Safety and human-robot collaboration: Ensuring safe interactions between humanoid robots and human workers is a priority. Robots must be equipped with advanced sensors and AI-driven safety protocols to prevent accidents. 

• Workforce transition: The integration of humanoid robots raises questions about workforce displacement. Automakers must invest in retraining programs to equip employees with skills relevant to an AI-driven production environment. 

• Technical limitations: While humanoid robots have made significant progress, challenges remain in areas such as dexterity, battery efficiency, and real-time decision-making under unpredictable conditions. 

The Future of humanoid robotics in automotive production 

Despite these challenges, the trajectory for humanoid robots in automotive manufacturing is clear. As AI and robotics technologies continue to evolve, their capabilities will expand, making them even more integral to production processes. 

In the coming years, we can expect: 

• Greater AI-driven autonomy: Robots that can self-diagnose issues, optimise workflows, and autonomously adapt to new tasks. Sanctuary AI and Deep Robotics are making strides in developing humanoids equipped with advanced AI systems that allow for real-time decision-making and adaptive learning in dynamic manufacturing environments. These technologies enable robots to adjust their actions based on shifting production needs or unexpected challenges, reducing downtime and improving efficiency. 

• Improved collaboration with human workers: Advanced human-robot interaction models that enable seamless teamwork between robots and factory employees. Boston Dynamics, famous for its Atlas robot, continues to push the envelope of robotic agility and flexibility, creating humanoids capable of performing physically demanding tasks in manufacturing and logistics. 

• Scalability in production: More automakers adopting humanoid robots at scale, reducing reliance on traditional automation models.  

The automotive industry has always been a pioneer in industrial automation, and the rise of humanoid robotics represents the next evolutionary step. Companies like BMW, Tesla, and Mercedes-Benz are paving the way for a future where AI-powered robots work alongside human teams to create safer, more efficient, and more flexible manufacturing ecosystems. 

With ongoing advancements in AI, machine learning, and robotics, the vision of a truly autonomous factory—where humanoid robots learn, adapt, and enhance production without human intervention—is closer than ever to becoming a reality.