Automation Humanoid Robots in Series Production at BMW in Germany

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Starting in summer 2026, humanoid robots will work in the series production of the BMW plant in Leipzig, Germany. They will change their batteries autonomously.

BMW is launching a pilot project with humanoid robots at the Leipzig plant. During the test and later in the pilot phase, the robots will work in the assembly of high-voltage batteries and in component production for exterior parts. The humanoid "AEON" robots are supplied by Zurich-based company Hexagon Robotics.

Hexagon presented Aeon in June 2025. It is the company's first humanoid robot. BMW tested the robot in Leipzig in December 2025. Aeon is now about to undergo a second test in April 2026 - with the aim of fully integrating it into production from summer 2026.

What the Humanoid "AEON" Can Do

The humanoid is wheeled and moves at a maximum speed of 2.4 m/s (approx. 7.9 ft/s). For comparison: humans walk at around 1.35 to 1.65 m/s (approx. 4.4 to 5.4 ft/s), i.e. around 4.9 to 6 kilometers per hour (approx. 3.0 to 3.7 mph). The robot weighs 60 kilograms (approx. 132 lb) and is 1.65 meters high (approx. 5.4 ft). Hexagon Robotics puts the payload at 15 kilograms (approx. 33 lb) for short periods and eight kilograms (approx. 18 lb) for long periods. According to the manufacturer, the battery life is four hours. According to BMW, hand and gripper elements or scanning tools can be docked on flexibly.

Aeon changes the battery itself at a station. To do this, he connects a hand to the battery to be changed. These are installed in two slots on the front of the humanoid. The battery slides out - the robot inserts it into a slot on the charging station. Next step: Aeon grabs the charged battery from the station and inserts it into its front. After 26 seconds, everything is done.

Aeon at the BMW Plant in Leipzig (Germany)

Humanoid Robots in Spartanburg

In 2025, BMW had the first humanoid robot in one of its plants. At the American plant in Spartanburg, "Figure 02" from the company Figure AI worked in the body shop. The robot removed sheet metal parts from boxes and positioned them in welding systems with millimetre precision. According to BMW, the humanoid moved over 90,000 components in total and covered around 1.2 million steps in around 1,250 hours of operation.

Within ten months, the robot helped build more than 30,000 BMW X3s. Its shift schedule: Monday to Friday, ten hours. "The use of humanoid robots met with great interest among employees and quickly became a natural part of everyday working life over the course of the project," BMW describes in a press release. The companies are currently looking into further deployments for the successor to Figure 03.

"Physical AI for Production"

For the use of physical AI, i.e. the combination of AI agents and robots, BMW uses a standardized IT and data model in the production system that runs on a data platform. This means that all data is consistent, standardized and available at all times. For example, AI agents can perform tasks autonomously and in complex environments. At the same time, they are continuously learning and qualifying for other areas of application.

BMW is pooling its expertise in artificial intelligence and robotics in a "Center of Competence for Physical AI in Production". "In recent years, we have already been able to build up an international team of experts who, in addition to in-house research and programming, have set themselves the task of successively integrating AI into the existing production system," explains Felix Haeckel, Group Manager of the Center of Competence. The aim is to set up and develop pilot projects with physical AI in other plants.