BMW Group is expanding its use of Physical AI in production, launching its first European pilot with humanoid robots at its Leipzig plant in Germany.

The carmaker said the Physical AI project aims to integrate AI-enabled humanoid robots into series car production, with initial use cases in high-voltage battery assembly and component manufacturing. The move builds on earlier trials in the United States and forms part of BMW’s wider digitalisation strategy under BMW iFACTORY.

“Digitalisation improves the competitiveness of our production – here in Europe and worldwide,” said Milan Nedeljković, Member of the Board of Management of BMW AG, Production. He added that combining engineering expertise with artificial intelligence (AI) opens up new possibilities in manufacturing.

Physical AI Expands From US To Europe

The Leipzig deployment follows a 2025 pilot at BMW’s Spartanburg plant in the United States, conducted with robotics firm Figure AI.

During that project, the humanoid robot Figure 02 supported production of more than 30,000 BMW X3 vehicles over 10 months. The robot handled the removal and positioning of sheet metal parts for welding, moving more than 90,000 components across roughly 1,250 operating hours, according to BMW.

The company said the pilot demonstrated that humanoid robots can perform precise, repetitive tasks safely in an automotive manufacturing environment. Insights from Spartanburg are now being applied to scale Physical AI in Europe.

At Leipzig, BMW is working with Hexagon Robotics, a division of Hexagon focused on sensor technology, software and humanoid robotics. Hexagon Robotics introduced its humanoid robot AEON in June 2025.

Following laboratory evaluations, AEON underwent an initial test deployment at BMW Group Plant Leipzig in December 2025. A further test phase is scheduled from April 2026, ahead of a full pilot planned for summer 2026.

The robot’s human-like design allows flexible attachment of different grippers and scanning tools. BMW said this supports multifunctional use across battery assembly and component production.

Unified Data Platform Enables AI Agents

BMW said artificial intelligence is already embedded across its production system, from digital twins in virtual factories to AI-driven quality control and autonomous transport systems.

A unified IT and data model underpins these efforts. The company has consolidated previously siloed production data into a single, standardised platform, allowing digital AI agents to take on more complex and autonomous tasks.

In combination with physical robots, these AI agents form the basis of Physical AI, enabling systems to learn and operate in dynamic industrial environments.

“Our aim is to be a technology leader and to integrate new technologies into production at an early stage,” said Michael Nikolaides, Senior Vice President Production Network, Supply Chain Management at BMW Group. He said pilot projects allow the company to test AI-enabled robots under real-world industrial conditions.

BMW has also set up a new Center of Competence for Physical AI in Production to consolidate internal expertise and manage partnerships. Technology partners are evaluated against defined industrialisation criteria before progressing from laboratory validation to plant-level pilots.

Complementing Existing Automation

The company said humanoid robotics will complement rather than replace existing automation. BMW sees potential in deploying Physical AI for monotonous, ergonomically demanding or safety-critical tasks, with the stated aim of relieving employees and improving working conditions.

Spartanburg’s body shop was selected for the US pilot due to its high level of automation and workforce experience with robotics integration. BMW noted that early engagement with production IT, occupational safety and shop floor logistics teams was critical to the project’s rollout.

The company and Figure AI are now evaluating further use cases for the next-generation Figure 03 robot, while the Leipzig pilot will test broader multifunctional applications of Physical AI in Europe.