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 in its production system meaning that all data is consistent, standardised, and 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. Particularly, they demonstrate potential in monotonous, ergonomically demanding, or 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 is following a clearly structured approach. Technology partners are evaluated according to defined maturity and industrialisation criteria and tested in pilot projects under real-world production conditions. Following a theoretical assessment, an evaluation is carried out at the manufacturer’s site in the laboratory using real use cases from the BMW production system to test integration capability. If this phase is successful, it is followed by an initial test deployment under real-world production conditions at a BMW Group plant and subsequently the actual pilot phase.

First pilot project with humanoid robots in Europe
In collaboration with Hexagon, a long‑standing, established partner of the BMW Group in the field of sensor technology and software, the first pilot project in Europe is now underway. Hexagon’s organisational unit located in Zürich, Hexagon Robotics, specialises in Physical AI and presented its first humanoid robot, AEON, in June 2025. Following an initial theoretical evaluation phase and successful laboratory tests, there was an initial test deployment at BMW Group Plant Leipzig in December 2025. A further test deployment is planned from April 2026 to ensure full integration for the actual pilot phase starting in summer 2026.

The deployment in Leipzig is focusing on testing a multifunctional application of the robot. It is based on AEON’s design, whose 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 the assembly of high‑voltage batteries and in 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 that Physical AI can deliver measurable added value under real-world conditions. Within ten months, the robot Figure 02 supported the production of more than 30,000 BMW X3, 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 particularly demanding in terms of speed and accuracy while also being physically exhausting. In total, it moved more than 90,000 components and covered approximately 1.2 million steps in around 1,250 operating hours.

The pilot confirmed that humanoid robots can safely perform precise, repetitive work steps – such as positioning components with millimetre precision – and provided important insights for the further deployment of Physical AI in production.

During the initial test phases with Figure 02, it was essential to involve all areas of the production IT infrastructure, occupational safety, production process management, and shop floor logistics at an early stage.

One key finding was that the transition from the laboratory to the actual production environment was faster than expected. Motion sequences trained in the laboratory 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 standardised interfaces.

The body shop was deliberately selected for the test phase in Spartanburg, as it already has a high degree of automation. BMW Group employees in this area have extensive experience in integrating new technologies and processes. For example, material supply on the line is already carried out almost exclusively via automated smart transport robots (STR). The project team’s early communication ensured transparency from the outset and promoted acceptance. The deployment of humanoid robots was met with great interest among employees and quickly became a natural part of everyday work during the course of the project.

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 at 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 to 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 in the 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 at 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.”

Note: This press release is a 1:1 copy of the original issued by BMW headquarters in Germany. No adaptions have been made to cater to the UK market.  

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 in its production system meaning that all data is consistent, standardised, and 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. Particularly, they demonstrate potential in monotonous, ergonomically demanding, or 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 is following a clearly structured approach. Technology partners are evaluated according to defined maturity and industrialisation criteria and tested in pilot projects under real-world production conditions. Following a theoretical assessment, an evaluation is carried out at the manufacturer’s site in the laboratory using real use cases from the BMW production system to test integration capability. If this phase is successful, it is followed by an initial test deployment under real-world production conditions at a BMW Group plant and subsequently the actual pilot phase.

First pilot project with humanoid robots in Europe

In collaboration with Hexagon, a long‑standing, established partner of the BMW Group in the field of sensor technology and software, the first pilot project in Europe is now underway. Hexagon’s organisational unit located in Zürich, Hexagon Robotics, specialises in Physical AI and presented its first humanoid robot, AEON, in June 2025. Following an initial theoretical evaluation phase and successful laboratory tests, there was an initial test deployment at BMW Group Plant Leipzig in December 2025. A further test deployment is planned from April 2026 to ensure full integration for the actual pilot phase starting in summer 2026.

The deployment in Leipzig is focusing on testing a multifunctional application of the robot. It is based on AEON’s design, whose 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 the assembly of high‑voltage batteries and in 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 that Physical AI can deliver measurable added value under real-world conditions. Within ten months, the robot Figure 02 supported the production of more than 30,000 BMW X3, 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 particularly demanding in terms of speed and accuracy while also being physically exhausting. In total, it moved more than 90,000 components and covered approximately 1.2 million steps in around 1,250 operating hours.

The pilot confirmed that humanoid robots can safely perform precise, repetitive work steps – such as positioning components with millimetre precision – and provided important insights for the further deployment of Physical AI in production.

During the initial test phases with Figure 02, it was essential to involve all areas of the production IT infrastructure, occupational safety, production process management, and shop floor logistics at an early stage.

One key finding was that the transition from the laboratory to the actual production environment was faster than expected. Motion sequences trained in the laboratory 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 standardised interfaces.

The body shop was deliberately selected for the test phase in Spartanburg, as it already has a high degree of automation. BMW Group employees in this area have extensive experience in integrating new technologies and processes. For example, material supply on the line is already carried out almost exclusively via automated smart transport robots (STR). The project team’s early communication ensured transparency from the outset and promoted acceptance. The deployment of humanoid robots was met with great interest among employees and quickly became a natural part of everyday work during the course of the project.

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 at 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 to 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 in the 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 at 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.”

Note: This press release is a 1:1 copy of the original issued by BMW headquarters in Germany. No adaptations have been made to cater for the UK market.  

Leipzig. Electrification continues at BMW Group Plant Leipzig: Four months after launching production of the combustion-engined MINI Countryman, the all-electric version is now rolling off the lines at Leipzig as well. After phasing out production of the BMW i3, the birthplace of electric mobility at the BMW Group has welcomed another fully electric car to its range. It now manufactures four models with three drive types by two brands, all on a single production line: the BMW 1 Series, the BMW 2 Series Active Tourer (including the plug-in hybrid version), the BMW 2 Series Gran Coupe and the MINI Countryman in both its fully electric and combustion-powered versions.

The MINI Countryman Electric represents a major step in the MINI brand’s transition to full electrification by 2030 and combines an electrified go-kart feel with zero local emissions mobility. It comes in two fully electric variants: the Countryman E (150 kW, 204 hp | electricity consumption 17.4 – 15.7 kWh/62 miles | CO2 emissions 0 g/mile) and the more powerful all-wheel Countryman SE ALL4 (230 kW, 313 hp | electricity consumption 18.5 – 16.8 kWh/62 miles | CO2 emissions 0 g/mile).  

Consistent plant upgrades and flexible production system

To enable production of up to 350,000 units a year – 100,000 more than previously – Plant Leipzig has been continuously upgraded since 2018, with extensive additions and upgrades to the bodyshop, paintshop, assembly and logistics. “Our cars and components are very much in demand. In recent years the BMW Group has invested around 1.6 billion euros in the Leipzig site to produce additional vehicles and electric components, and now we’re increasing vehicle volumes too – which is great news for our plant,” said Petra Peterhänsel, Plant Director.

The main driver behind the volume increase is the MINI Countryman. During the course of 2024, output will rise to almost 500 units a day – on top of the 800 or so BMW vehicles the plant is producing. What’s more, thanks to its flexible production system, Plant Leipzig is in a position to respond quickly to customer demand, for example by increasing the share of fully electric vehicles.

Flexible assembly structures also meant the MINI Countryman Electric could be integrated seamlessly into production. The situation is similar with the different drive units, which are all produced on one and the same line in aggregate assembly and prepared for what’s known as “marriage” with the body. The e-drives, transmissions and control electronics (collectively known as the highly integrated electric drive topology, or HEAT) for the two all-electric models are connected directly in the plant. A new production line was required only for the control electronics.

More staff and nightshifts for increased production volume

Higher production volume means secure employment and up to 900 additional employees in vehicle production alone. By the end of 2024, Plant Leipzig will employ around 7,000 BMW staff. Working hours will need to be adjusted in all technologies, with nightshifts in assembly starting for the first time in September of this year and cars being produced round the clock in three shifts.

“Plant Leipzig first went on stream in 2005 with about 2,600 employees in production. 19 years later there are over 7,000. Over the years, the plant has grown steadily and considerably. The start of nightshifts in assembly represents another important milestone in the success story of our plant and is a clear show of confidence by our company in our site here in Leipzig,” emphasised Works Council Chairman Jens Köhler.

Made at Plant Leipzig: high-voltage batteries for the MINI Countryman Electric

With the production launch of the MINI Countryman Electric, all three stages of the Gen 5 high-voltage battery production process are now represented at BMW Group Plant Leipzig: cell coating, module production and battery assembly. Operations in all three are currently ramping up, with five cell-coating, three module-production and two high-voltage battery-production lines now in place.

“We are in the middle of the transformation to e-mobility,” said Markus Fallböhmer, Head of Battery Production at the BMW Group. “Starting this year, Plant Leipzig will carry out every stage of our in-house high-voltage battery production process. It’s our next great step forwards.”

Plant Leipzig’s e-component production capacity has been increasing since 2021. It will now manufacture not just the high-voltage batteries for the MINI Countryman Electric but also e-components for the BMW iX1, BMW iX2, BMW i4, BMW i5 and BMW iX made at other sites. The e-component production unit at Leipzig currently employs some 1,000 people.

To enable production of high-voltage batteries, spaces previously used for the BMW i3 and BMW i8 have been converted and new buildings added. One of them is a new hall with a footprint of about 61,000 m². This houses two lines capable of producing up to 300,000 high-voltage batteries a year. The BMW Group has invested over 900 million euros in e-component production at Plant Leipzig to date.

Resource-saving painting processes

At launch, the fully electric MINI Countryman comes in three additional body colours: British Racing Green, Chili Red and Blazing Blue – and with MINI’s trademark contrast roof, if desired. This is painted using a new overspray-free method that saves resources and is currently being readied for series operation. The term “overspray” refers to the mist of excess paint particles that forms when bodies are painted the conventional way. With the new technique, this mist no longer occurs. This makes it easier to paint in multiple colours as the laborious process of masking is no longer required. Overspray-free painting also helps save CO₂ emissions, as exhaust from the cabin requires less cleansing. In addition, it requires considerably less conditioned air, i.e. air that is brought to the exact temperature and humidity required for painting. As a result, less energy is needed to temper air and treat exhaust.

The burner technology used to dry the paint on contrast roofs was also converted for the start of MINI Countryman production and now consists of a bivalent system. The fuel-flexible burners can run on hydrogen (H2) as well as gas (methane, CH4) and even switch between the two while in operation. Five such bivalent hydrogen-capable burners are used to produce the contrast roofs for the MINI Countryman.

Further burners in the paintshop will also gradually switch to bivalent operations, with the next six hydrogen-capable burners just installed. This makes Leipzig a pioneer in the automotive industry and takes it ever closer to lower CO₂ emissions. “Our vision at Plant Leipzig is to decarbonise production as far as possible by replacing fossil fuels with green hydrogen,” said Petra Peterhänsel, explaining the long-term focus of the facility. This will require sufficient green hydrogen from a grid. A regional hydrogen grid is currently in planning, with Plant Leipzig set to benefit.