BMW Group is accelerating the use of digitalization and artificial intelligence in manufacturing, with a growing focus on what it calls “Physical AI.” The idea is straightforward in concept but ambitious in execution. Software-based AI systems are linked directly with real-world machines and robots, so intelligent systems can participate in live production tasks rather than staying confined to analytics dashboards or simulation environments. BMW says this approach could unlock new ways to automate repetitive work, improve quality consistency, and reduce physical strain on employees.
BMW is now bringing that physical AI concept into European vehicle production through a pilot project using humanoid robots at its Leipzig plant in Germany. The stated goal is to integrate humanoid robotics into existing series production while also testing additional use cases in battery and component manufacturing. Similar humanoid trials are underway across the industry, including efforts by Mercedes Benz, Tesla, and several Chinese automakers.
A Leadership Message Tied To A Broader Manufacturing Push
BMW frames the initiative as part of a larger manufacturing strategy that combines engineering know-how with AI-driven systems across the production network. Milan Nedeljković, BMW AG board member responsible for production, has emphasized that digitalization is a competitiveness tool both in Europe and globally. BMW has also confirmed that Nedeljković will become Chairman of the Board of Management of BMW AG effective May 14, 2026, succeeding Oliver Zipse.
The Data Foundation Behind Physical AI
BMW says one of the prerequisites for meaningful AI deployment is a unified IT and data model across the manufacturing system. In practical terms, that means consolidating previously separated data silos into a standardized platform so information remains consistent and continuously available. With that foundation, BMW believes digital AI agents can take on increasingly complex tasks, learn from outcomes, and adapt to new applications across different factory environments.
When those digital agents are paired with robots, BMW describes the result as physical AI, including AI-supported, self-learning robotic systems that can operate in real industrial conditions.
The European Pilot With Hexagon Robotics And Aeon
For the Leipzig pilot, BMW is working with Hexagon, a long-time partner known for sensor technology and industrial software. Hexagon’s robotics unit introduced its humanoid robot called AEON in June 2025, positioning it as an industrially focused platform designed for real workplace needs.
BMW says the first test run in Leipzig took place in December 2025, with another test planned starting in April 2026 to support full integration ahead of a broader pilot phase expected to begin in summer 2026.
In Leipzig, the focus is on flexible, multipurpose tasks. AEON’s humanoid form is intended to allow tool changes, including different grippers and scanning tools, while its wheeled mobility is designed to help it move dynamically through the plant. Planned use cases include the assembly of high-voltage battery systems for electric vehicles and selected component production tasks.
What BMW Learned From Its Earlier U.S. Trial
BMW’s European work builds on an earlier humanoid robot deployment at BMW Group Plant Spartanburg in South Carolina in 2025, conducted with Figure AI. BMW reports that over a ten-month period, the Figure 02 robot supported production of more than 30,000 BMW X3 units while working ten-hour shifts from Monday through Friday. The robot handled precise picking and positioning of sheet metal parts for welding-related processes, manipulated more than 90,000 parts, and logged roughly 1.2 million steps in about 1,250 working hours.
BMW says that the trial demonstrated reliable performance on repetitive operations, including millimeter-accurate positioning, and that moving from lab testing into a real production environment happened faster than expected.
Why Humanoid Robots Are Being Considered
BMW is presenting humanoid robots as an addition to existing automation, especially for monotonous, physically demanding, or safety-sensitive jobs. The company also says it has created a dedicated competence center for physical AI in production to consolidate expertise and scale validated applications across its network.
For BMW, the Leipzig pilot is a practical test of whether humanoid robots can deliver measurable value alongside traditional industrial automation, particularly in EV battery-related work where ergonomics, precision, and process consistency matter every day.
This article originally appeared on Autorepublika.com and has been republished with permission by Guessing Headlights. AI-assisted translation was used, followed by human editing and review.