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 Nedeljkovic, 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 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.
First pilot project with humanoid robots in Europe
In collaboration with Hexagon, a long-standing 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, 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.