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What changed for humanoid robots in 2025?
The important shift was from showing what a humanoid might do to testing one in an operating production environment. BMW said its Spartanburg pilot was the first humanoid deployment at a BMW plant. Other companies announced industrial pilots, but an announced pilot or intended use is not the same as a verified production result.
That distinction matters because a factory robot is part of a larger system: it must work alongside people, production equipment, material flows, safety procedures, and maintenance routines. A human-shaped form may be useful where a task or workspace suits it, but shape alone does not establish an advantage over a fixed robot or other automation.
What did BMW report at its Spartanburg plant?
BMW said Figure 02 worked in the plant’s body shop, removing and positioning sheet-metal parts for welding. The company described the job as requiring precise handling. BMW said the pilot ran for ten months, with the robot working ten-hour weekday shifts, and supported production of more than 30,000 BMW X3 vehicles.
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BMW also reported that the robot moved more than 90,000 components and took approximately 1.2 million steps in around 1,250 operating hours. These are figures reported by BMW, not independently audited measurements or a head-to-head productivity study. They show the scale BMW says the pilot reached; they do not by themselves establish a cost or output advantage.
Why the factory setup matters
BMW said it chose a body shop with a high degree of automation and involved production IT, occupational safety, process management, and shop-floor logistics early. It also said the robot was integrated into its Smart Robotics ecosystem using standardized interfaces. Those details underline that deployment involves more than the robot’s AI: the task, line equipment, material handling, software connections, and workplace procedures all have to fit together.
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Which industrial pilots were announced next?
On June 17, 2025, Hexagon announced AEON and described intended industrial uses including manipulation, asset inspection, reality capture, and operator support. Hexagon named Schaeffler and Pilatus as partners for pilots exploring manipulation, machine tending, part inspection, and reality capture. These were announced pilot plans and intended applications; the announcement alone does not establish operational results for those tasks.
Hexagon described battery swapping and multimodal sensing as AEON design features. Those are vendor descriptions, rather than independent findings about uptime or performance. Hexagon Robotics division President Arnaud Robert said: “With AEON, we’re advancing physical AI to tackle real operational challenges – bridging cutting-edge technology with practical industry needs.” This is the company’s characterization of its goals.
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How do humanoids fit into the broader automation trend?
Humanoids are one part of a wider push to use AI and simulation in industrial settings. NVIDIA describes work on robot-fleet simulation and factory digital twins, which can help companies model production environments and physical-AI systems. NVIDIA reported $1.2 trillion in U.S. production-capacity investment announcements in 2025; that figure concerns production capacity generally, not investment in humanoid robots.
BMW’s Michael Nikolaides, Senior Vice President Production Network, Supply Chain Management at BMW Group, described the purpose of pilots this way: “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.” A pilot can provide experience in a real workplace, but its existence is not proof that the technology is ready for broad use.
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What do the 2025 reports establish—and what remains unproven?
| Question | What the available reports establish | What they do not establish |
|---|---|---|
| Are humanoids being tried in factories? | BMW reported a production pilot at Spartanburg; Hexagon announced industrial pilots with Schaeffler and Pilatus. | That announced applications at other sites produced verified operational results. |
| Are humanoids replacing factory workers generally? | BMW reported a robot performing a defined sheet-metal handling task. | General replacement of factory workers or broad commercial adoption. |
| Do humanoids outperform conventional automation? | The reports describe tasks, integration, and pilot activity. | Comparable productivity across models, lower total cost than fixed automation, or a demonstrated overall advantage. |
| Is the market already broad? | A 2025 Associated Press account described the humanoid market as narrow at that time and reported a Unitree G1 trade-show demonstration. | A current market-size or price conclusion. The account’s price and buyer description were attributed to a company representative, not established as a current quote. |
The most useful comparison is task-specific: what the robot must handle, the precision and cycle time required, uptime and maintenance needs, integration with line equipment and logistics, worker safeguards, and independently supported cost or productivity results. The cited reports help describe the task, integration, and safety dimensions; they do not provide an apples-to-apples economic comparison.
Independent reader supportYour contribution helps us test, update, and keep practical guides available for everyone.What safety requirements apply?
OSHA says there are currently no specific OSHA standards for the robotics industry. That does not mean a robot deployment is unregulated or exempt from workplace obligations: employers must consider applicable workplace rules and relevant consensus standards. OSHA’s Technical Manual recommends risk assessment at each stage of a robot application, from design and integration through operation and maintenance, with safeguarding and training appropriate to the particular application.
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ISO’s 2025 catalog describes ISO 10218-1:2025 as covering safety requirements for industrial robots and ISO 10218-2:2025 as covering integration and robot applications. Their defined scopes should not be mistaken for a humanoid-specific certification, nor does the existence of a standard establish that a particular robot or installation is safe. Employers need to check the current applicable editions and requirements for the actual deployment.
Quick Recap
Practical questions for evaluating a pilot
- Task: Is the job specific and repeatable enough to assess, and what precision, cycle time, and payload does it require?
- Workcell: How will the robot interface with production equipment, software, and material logistics?
- Reliability: What uptime, maintenance, recovery, and operator-support needs have been measured in the intended environment?
- Safety: Has the application been risk-assessed across integration, operation, and maintenance, with suitable safeguards and worker training?
- Value: Is there independently supported evidence comparing total costs and task performance with the relevant alternative, such as fixed automation?
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