Artificial Intelligence Humanoid Robots: Am I Able to Work Here?

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Is the ultimate automation solution coming with AI-driven humanoid robots? Some experts are skeptical and question the maturity of the robots.

Audi, BMW, BYD, FAW-Volkswagen, Geely, Magna, Mercedes-Benz, Nio, Tesla, Schaeffler: These are some examples of automotive companies that have already tested or plan to test humanoid robots equipped with artificial intelligence. Why this rush for bipedal robots? If everything works as hoped, humanoids can economically automate almost any task—including activities that previously could only be performed by humans or whose automation was not cost-effective.

As bipeds, the robots can easily operate in environments designed for humans. Continuously improved sensor technology allows robots to "feel" and perceive their surroundings. And to perform varying tasks, the robot doesn't need to be redesigned but simply trained for new activities. Software, especially AI, makes this possible—following the software-defined vehicle comes software-defined automation.

Automakers Test Humanoid Robots

As the first OEM, BMW has gone public in a big way with the testing of humanoid robots at its Spartanburg plant in the U.S.. In mid-2024, humanoids of the Figure 02 type were tested there for several weeks, placing sheet metal parts into fixtures for welding in the body shop. Currently, the robots are back at the Spartanburg plant for another pilot deployment, with BMW and Figure experts continuously optimizing them.

A robot moves 1,000 sheets per day according to BMW. The machines, according to the manufacturer Figure, weigh 70 kilograms, are approximately 1.7 meters tall (approx. 5.5 ft), and can carry 20 kilograms. "We want to accompany this technology from development to industrialization," said BMW's Head of Production Milan Nedeljković.

Mercedes-Benz is testing several Apollo robots from the Texas-based company Apptronik at its Berlin Digital Factory Campus and in production plants. The humanoids are intended to learn to independently execute defined motion sequences. The OEM's initial target areas are intralogistics, including material transport, sorting, and component inspection. Once a certain level of maturity is reached, Apollo is expected to be "gradually more integrated into production."

The Apollos have similar key specifications to the Figure 02: about 1.73 meters tall (approx. 5.7 ft), weighing 73 kilograms, and capable of carrying around 25 kilograms. To strengthen collaboration with Apollo, Mercedes-Benz plans to invest "a low double-digit million amount" in Apptronik in 2025.

Several Humanoid Robots at Schaeffler

The supplier Schaeffler is already "deploying several humanoids in pilot phases within the global production network, including in Cheraw, USA," as a company spokeswoman told Automobil Industrie (German magazine). These include models from the US manufacturer Agility Robotics, in which Schaeffler holds a 1.1 percent stake, and robots from other manufacturers.

At the Hannover Messe (German trade fair), Schaeffler, together with IT service provider and consultant Accenture, demonstrated how the humanoid robots "Digit" from Agility Robotics and "Phoenix" from Sanctuary AI can be utilized in digitized factory environments. Accenture holds a minority stake in the Canadian company Sanctuary AI. Magna has also been involved with Sanctuary AI since 2021 and is expected to support the industrialization of the robots. Schaeffler aims to position itself as a component supplier for humanoid robots, providing items such as joints or drives.

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Environmental Sensors From the Car

The dimensions of computing power in humanoid robots are exemplified by Xpeng. The OEM, in which the Volkswagen brand holds a 4.99 percent stake, builds its own humanoid robots. In a video, Chairman and CEO He Xiapen emphasizes that the robots use the Eagle-Eye system for environmental perception, which is also deployed in the new P7+ sedan—and even more AI power than in the car.

However, a machine in human form is not necessarily the best solution for every automation task. For example, walking requires significantly more energy than rolling. The movement itself is more energy-intensive. Additionally, the robot requires a great deal of power-hungry computing resources to remain stable on two legs. This reduces the battery life of robots, which currently is usually a maximum of four hours.

Humans and robots also differ in the number of joints: Humans have 140 real joints, and including so-called pseudo joints, like intervertebral discs, the number rises to 212. Robots, on the other hand, have to make do with 25 to 30 joints. However, in other aspects, despite their human-like appearance, robots can surpass the original: for example, achieving 360-degree rotations at joints.

Two- or Four-Legged or on Wheels

Robot manufacturers are also thinking about such issues. Boston Dynamics, for example—80 percent owned by Hyundai—has the bipedal Atlas robot underway. However, while Atlas, like all humanoids, is still awaiting industrialization, the Spot robot from Boston Dynamics has been walking on four legs for some time now, including in plants operated by Audi and BMW. There, the robot dog scans the facilities to create digital twins or assists "as a watchdog for maintaining production equipment" at BMW's Hams Hall facility in the UK. Apptronik takes a different approach. Its Apollo robots are not only offered in fully humanoid form. Since two legs are often unnecessary, customers can also opt for the torso mounted on a mobile base with wheels or on a fixed platform.

What Jobs for Humanoid Robots?

What could the role of bipedal robots look like in the factory of the future? They are expected to relieve humans, free them from dangerous tasks, and collaborate with them, according to frequently mentioned scenarios. And they could counteract the skills shortage.

The extent to which they will replace humans remains to be seen. A study by market research company Nexery estimates a payback period of about 1.4 years for the first serially produced robots. In the short term, they could automate more than 40 percent of human activities. Author Tobias Bock anticipates declining costs and increasing capabilities. By 2030, he expects a return on investment within just over half a year or less.

Humanoid robots are also classified as one of the top five trends by the International Federation of Robotics. However, it remains "to be seen whether humanoid robots will represent an economically viable and scalable business case for broad industrial application." Fraunhofer researchers have also recently expressed significant caution. While they acknowledged the potential to "become a game changer in existing factories," based on feedback from 100 industry experts, they noted that, with the current level of technological maturity, the use of humanoid robots in production and logistics is "still to be considered a misguided path."

The robot manufacturers naturally believe in their success and are planning industrialization. Apptronik has recently entered into a partnership with the contract manufacturer Jabil from Florida, which also counts Apple among its clients. Figure has just announced plans to establish a robot manufacturing facility where humanoid robots will produce new humanoid robots. This is set to happen later this year. At the start of production (SOP), the capacity will be 12,000 robots per year.

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