March 16, 2026 BMW has begun deploying AI-powered humanoid robots in electric vehicle production at its Leipzig iFACTORY, expanding earlier automation trials conducted at the company’s Spartanburg, South Carolina plant. The robots are designed to handle manufacturing tasks such as positioning sheet metal for welding and navigating factory environments alongside human workers.
The new machines, called AEON robots and developed by Zurich-based Hexagon Robotics, use sensors and AI-based motion control to assess their surroundings and make operational decisions while avoiding obstacles and people on the production floor.
“Our aim is to be a technology leader and to integrate new technologies into production at an early stage,” said Michael Nikolaides, senior vice-president for production network and supply chain management at BMW Group.
BMW’s earlier pilot with humanoid robots involved Figure 02 units operating at its Spartanburg facility, where the machines helped support the production of more than 30,000 BMW X3 vehicles. Those robots focused primarily on handling repetitive and precision-oriented tasks within the manufacturing process.
The AEON robots being introduced at the Leipzig facility are designed to expand that capability. According to Hexagon, the systems rely on what it describes as “Physical AI,” software that allows robots to interpret their environment and adjust actions in real time during production operations.
The robots’ humanoid form allows engineers to model robotic tasks on human movements already used in assembly processes. This approach can simplify workflow planning and help integrate robotic automation into existing factory layouts.
BMW says the project forms part of its broader iFACTORY strategy, which focuses on integrating digital tools, automation and AI into vehicle manufacturing. The initiative aims to improve production efficiency while supporting the transition to electric vehicle manufacturing.
“Digitalization improves the competitiveness of our production, here in Europe and worldwide,” said Milan Nedeljković, member of the board of management of BMW AG responsible for production.
