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.”

+++ Export Value in 2024 Totaled $10.1 Billion +++ From 2014-2024, BMW’s Export Value Totaled more than $100 Billion +++ Plant Preparing to Assemble Fully Electric BMWs in 2026 +++ Board Member Nedeljković: “Strong export share of our plant underlines the importance of free trade” +++

Spartanburg, S.C. – BMW Manufacturing has confirmed that it was the leading automotive exporter by value in the United States in 2024, according to data released this month by the U.S. Department of Commerce. ##Plant Spartanburg## exported nearly 225,000 BMW Sports Activity Vehicles and Coupes last year with an export value of more than $10 billion. Moreover, since 2014, the South Carolina plant has exported more than 2.7 million BMWs – about 63 percent of total production – with an export value of more than $104 billion.

“Plant Spartanburg has been an important location in our production network for over 30 years and is now the largest BMW Group plant globally,” explained Milan Nedeljković, Member of the Board of Management of BMW AG, Production. “The strong export share of our plant underlines the importance of free trade for the USA. Not only does this benefit our plant, but also the strong supplier network in the region.”

“When the first BMW rolled off the assembly line in 1994, it was the beginning of a great legacy for Plant Spartanburg in the United States. Our dedicated associates have assembled nearly seven million BMWs, and because of our export success, millions of customers around the world experience the innovative technology and premium quality of our X vehicles,” said Robert Engelhorn, president and CEO of BMW Manufacturing. “Our achievement as the country’s leading automotive exporter demonstrates BMW’s trusted partnership with this state and our continued commitment to the United States.”

"South Carolina's position as a stronghold for the United States' automotive industry can be traced directly to BMW's success in our state. The BMW models assembled at Plant Spartanburg are in global demand — shipping to markets around the world,” said South Carolina Governor Henry McMaster. “We are proud to have a company as committed to the prosperity of its community, the success of its employees, and the innovation of its industry right here in South Carolina. We look forward to celebrating many more milestones with BMW in the years ahead."

The BMWs assembled at the South Carolina plant were exported primarily through the Port of Charleston, SC, as well as through four additional ports on the East Coast. The top export markets from Plant Spartanburg were Germany, South Korea, China, Canada, and Great Britain.

Plant Highlights from 2024

The team at BMW Manufacturing assembled 396,117 Sports Activity Vehicles and Coupes last year. As part of that total, more than 57,000 plug-in hybrid electric vehicles were assembled, which made up more than 14 percent of the plant’s total volume. Nearly 50 percent of all BMWs sold in the U.S. were assembled at Plant Spartanburg.

Other plant highlights from 2024 include:

• Associates successfully launched the fourth-generation BMW X3, one of the best-selling BMWs in America.
• While celebrating the 30th anniversary of Plant Spartanburg, BMW opened its first press shop in North America. The state-of-the-art press shop stamps parts for the BMW X3, including hang-on parts such as the vehicle’s four doors, fenders, lift gate, and exterior body sides.
• The expansion of the X3/X4 assembly hall continued as Plant Spartanburg prepares to assemble fully electric vehicles. Construction is complete, and most tooling and equipment has been installed. The first electric vehicle will be shipped in late 2026, and by 2030, the BMW Group will assemble at least six fully electric models in the U.S.
• Construction at Plant Woodruff, BMW’s new $700 million high-voltage battery assembly plant: Tooling and equipment is being installed with all work substantially completed by the end of March 2025. Associates at the one million square foot facility will assemble the sixth-generation batteries to supply fully electric vehicles at Plant Spartanburg.
• Construction on an expansion to the main body shop was completed, and an additional 300+ robots have been installed.
• Construction on a new eight-story body shop stacker for vehicle storage was completed.

Since 1992, the BMW Group has invested more than $14.8 billion in its South Carolina operations. BMW Manufacturing is the largest BMW Group plant in the world, assembling more than 1,500 vehicles each day. Nearly 57 percent of its vehicles are shipped to about 120 global markets, making BMW the largest automotive exporter by value in the United States for more than a decade. In 2024, nearly 50 percent of BMW vehicles sold in the U.S. came from Plant #Spartanburg. It employs more than 11,000 people. 

Munich. The BMW Group is accelerating its ramp-up of e-mobility and increasingly relying on regional supply chains, in line with the principle “local for local”. The company aims to source components like battery cells close to vehicle production and gradually localise the supply chain for primary materials.

New partner to supply primary material for battery cell production

Belgian company Umicore has now been recruited as a further partner for establishing a local supply chain in North America. Umicore will supply our battery cell supplier AESC with cathode active battery materials from a new plant in #Ontario, Canada. This is an important step in strengthening the BMW Group's regional supply chains and securing the ramp-up of e-mobility.

In accordance with the “local for local” principle, our partner AESC is currently building a battery cell factory in #Florence, ##South Carolina##. With an initial capacity of 30 GWh/a, the facility will produce the innovative cylindrical lithium-ion battery cells specifically developed for the sixth generation of ##BMW eDrive## technology. Electricity for production of the battery cells and cathode raw material will come exclusively from renewable sources.

“The BMW Group pursues a globally balanced procurement strategy in the three main geographical regions of the world. Our battery cell supplier in the US will source key primary materials from Canada going forward. We are pleased that Canada is playing a strong role in establishing a robust and efficient battery cell supply chain for the BMW Group in North America,” said Joachim Post, member of the Board of Management of BMW AG responsible for Purchasing and Supplier Network.

Further BMW Group investment in South Carolina

Oliver Zipse, Chairman of the Board of Management of BMW AG, already announced an extensive investment of 1.7 billion US dollars in expansion of the US production site back in October 2022. This includes 700 million US dollars to build the BMW Group’s new assembly centre in #Woodruff, which will provide high-voltage batteries for the fully-electric BMW X models in the future. In the initial phase, the roughly 93,000 sq. m. facility will produce sixth-generation battery modules. The assembly centre will also create about 300 new jobs.

Sixth-generation battery cell technology for better performance and sustainability

The new sixth-generation battery format will increase energy density by more than 20 percent and improve charging speed and range by up to 30 percent. At the same time, CO₂ emissions from cell production will be reduced by up to 60 percent: on the one hand, by cell suppliers relying on energy from renewable resources; on the other, by using a percentage of secondary material for the raw materials lithium, cobalt and nickel.