Cost-Effective Support Igus Turns Humanoid Robots Into Everyday Tools

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They could become universal helpers in the factories of tomorrow: humanoid robots. However, there are high entry barriers, as many models are too complex and expensive. This is where Igus comes in with its low-cost automation expertise, introducing its first humanoid robot. The "Iggy Rob" is not only affordable but also quickly ready for use—thanks to the mobile platform Rebel Move.

They are true workhorses: robots tirelessly perform a wide variety of tasks and have become indispensable in the industry. Above all, they excel at one thing – completing the tasks assigned to them quickly and reliably. However, what has gained importance over the past years and decades is now reaching its limits. Many tasks in factories are not entirely repetitive, stationary robots often remain isolated solutions, and therefore do not achieve a quick return on investment.

It is therefore not surprising that great hopes are placed on humanoid robots internationally. Voices from Silicon Valley suggest that by 2040, there could be more humanoid robots than humans on Earth. Even more conservative estimates, such as those from the management consultancy Horváth, forecast significant growth starting in 2025. The often-consulted Gartner Hype Cycle expects significant disruptions in supply chains in the near future. The automotive industry, in particular, is currently leading the way with several projects – here, humanoid robots often take over the task of transporting heavy components.

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For serial deployment, the human-like helpers are mostly not yet ready. Even Gartner expects their permanent establishment in the market only in about ten years. The reasons for this are diverse—one of them is the price: Humanoid robots are very expensive, often costing 80,000 euros (approx. 93,500 USD) or more in the industry. However, the Horváth study estimates that the systems could soon drop in price to around 48,000 euros (currently approx. 56,074 USD). Proving this estimate right is the Iggy Rob from Igus, which, at a price of 47,999 euros (currently approx. 56,072 USD), serves as a low-cost solution capable of performing a variety of tasks in industry and society.

Movement With Almost no Restrictions

Humanoid robots are characterized primarily by their mobility, allowing them to move from one area of the factory to another. If the systems are equipped with legs, even steps pose no problem. With their arms, they perform gripping tasks throughout the production process and, thanks to artificial intelligence, know exactly what to do. The Iggy Rob from Igus can transport components, work as a service robot at reception, or bring dishes to the sink in the cafeteria. All the while, it always greets its colleagues with a smile on its virtual face.

The time is now ripe for humanoid robots.

Alexander Mühlens, Head of the Low-Cost Automation business unit at Igus

That it is the plastics specialist Igus that has managed to develop its own functional humanoid robot in a relatively short period of time is no coincidence. "We have been working on humanoid robotics since 2014," says Alexander Mühlens, Head of the Low-Cost Automation business unit at Igus. The Cobot Rebel has long been established and is now used in many industrial applications. Up to 40 new cobots leave the Igus factories each week, with the robotic arm in demand worldwide. The importance of autonomous mobile robots (AMRs) is also well recognized at the company headquarters in Cologne. The Rebel Move automates logistics processes, moving loads of up to 50 kilograms. On the robotics platform RBTX.com, companies can find their automation solutions in a portfolio from various manufacturers, ranging from pick-and-place applications to grinding machines. Taking the next logical step to venture into humanoid robotics was inevitable. "The time for this is now ripe," explains Mühlens. Since the end of 2024, there has been a noticeably growing interest from customers.

Recognizing Objects for Seamless Navigation

The Iggy Rob is approximately 1.70 meters tall (approx. 5.6 ft) and equipped with almost everything one would expect from a humanoid robot. The head features a display with facial expressions. Lidar sensors and 3D cameras in the chest area and the vehicle are used for object detection, enabling the Iggy Rob to navigate seamlessly through factories, lobbies, or cafeterias.

For its two arms, Igus has chosen a proven technology from its own lineup: with two Rebel cobot arms and bionic hands, the robot grips like a human. The Rebel arms provide mobility thanks to their six axes, with a total reach of 664 millimeters (approx. 26 inches). At a speed of up to 45 degrees per second, the Rebels are quick, and each arm can transport a weight of up to two kilograms.

Unlike many manufacturers, Igus has opted against legs for the Iggy Rob—for practical reasons. For mobility, the robotics experts have relied on the automotive mobile robot (AMR) Rebel Move. With a payload capacity of 50 kilograms and an additional load capacity of 100 kilograms, the robot moves flexibly through factory halls. Thanks to its three-point support system, the mobile platform is extremely stable. Additionally, many factory environments are already equipped or being equipped with infrastructure for AMRs. On a single battery charge, the Iggy Rob can work continuously for up to eight hours.

Intuitive Robot Programming and Control With Proprietary Software

The Cologne-based company delivers the robot with its in-house Igus Robot Control software, which enables simple and intuitive robot programming and control. Thanks to its modular design, the software allows companies to control various robotic kinematics. In addition to delta, gantry, and multi-axis joint robots, the Iggy Rob is now also included. Users can simulate the robot's individual movements on a 3D interface with the software, without the Iggy Rob needing to be connected. Through the specially developed ROS2 interface of the AMR, the humanoid helper is seamlessly integrable into modern robotic environments. According to the VDE 5050 interface, the Iggy Rob is approved for fleet management and has CE certification.

Great Potential for the Future

The Igus team is convinced that the potential applications for humanoid robots like the Iggy Rob will increase significantly. "Robots will be able to navigate the world created for humans much better in the future," predicts Alexander Mühlens. He expects humanoid robots to be used in areas such as metalworking or along the supply chain. At Igus itself, the Iggy Rob is already firmly planned—the plastics specialists intend to use it for loading components into their injection molding machines. Alexander Mühlens estimates that companies in mechanical engineering will be the first to adopt these innovative robots on a large scale.

Test Phase Even Before Purchase

Humanoid robots like the Iggy Rob are still uncharted territory for many companies—Igus is well aware of this. That’s why the company is taking a unique approach: the further development of the robot happens in collaboration with customers. Before purchase, the manufacturer offers a "test-before-invest" program. The Igus robotics team then analyzes the deployment potential on-site at the customer’s location without requiring a purchase agreement. If the evaluation is positive, nothing stands in the way of acquisition. The trend is clear: humanoid robotics will gain significant importance—and the Iggy Rob, with its comparatively low purchase price, is the ideal starting point for this.

*Christoph Föttinger is Managing Director of Drytech Bearing Technology at Igus Polymer Innovations GmbH in Lenzing (Austria)

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