BMW Group has expanded its use of Physical AI in manufacturing by introducing the next-generation Figure 03 humanoid robot at its Spartanburg plant in the US.

Building on the successful deployment of Figure 02, the new robot will handle complex sequencing tasks in logistics as part of the automaker’s push toward AI-driven production.

“Our 11-month deployment of Figure 02 proved that humanoids are no longer lab experiments – they can be a valuable asset in establishing a flexible, reliable manufacturing workforce,” said Brett Adcock, Founder and CEO of Figure AI, in a statement.

In March 2026, BMW expanded its Physical AI with a Leipzig pilot, a new AI hub, and an AEON humanoid robot, following successful deployments at its Spartanburg plant.

Smarter factory robotics

Following a successful 10-month pilot with Figure AI’s Figure 02 humanoid robot, the automaker is deploying the next-generation Figure 03 robot to automate complex sequencing tasks in production logistics.

According to BMW, the latest deployment marks a shift from body shop operations to logistics, where Figure 03 will organize unsorted components into sequencing trolleys before they are delivered to assembly stations by autonomous transport systems. The process supports “just-in-sequence” manufacturing, ensuring workers receive the correct components at the right time while reducing repetitive manual handling.

BMW’s earlier collaboration with Figure AI demonstrated the practical value of humanoid robots in industrial environments. During the pilot, Figure 02 helped produce more than 30,000 BMW X3 vehicles by inserting sheet-metal components into welding fixtures. According to a statement by BMW, the task required high precision, speed, and consistency while relieving workers of physically demanding operations. The project showed that humanoid robots can safely perform repetitive, high-accuracy tasks alongside human employees under real production conditions.

Building on those results, Figure 03 introduces significant hardware and software improvements designed for broader manufacturing applications. The humanoid features soft exterior components to improve workplace safety, wireless charging to maximize operational uptime, and speech-to-speech communication capabilities for more natural interaction with workers. It also incorporates redesigned robotic hands equipped with tactile sensors and integrated palm cameras, enabling greater dexterity, improved object recognition, and more precise manipulation of production parts.

According to Figure AI, the previous deployment proved that humanoid robots are now practical manufacturing tools rather than experimental technologies. BMW’s production leadership also views Spartanburg as the company’s primary development site for integrating humanoid robotics into daily factory operations.

AI powers production

BMW is also in the process of deploying Physical AI in Europe for the first time with a pilot project at its Leipzig plant in Germany, where humanoid robots will be integrated into vehicle production. The company is testing Hexagon’s AEON humanoid robot for battery assembly and component manufacturing after successful laboratory trials and initial factory deployments.

Equipped with modular grippers, scanning systems, and wheeled mobility, AEON is designed to perform multiple manufacturing tasks. The pilot will evaluate the robot’s versatility across production processes, particularly in high-voltage battery manufacturing, energy module production, and the assembly of exterior vehicle components.

The humanoid robot initiative forms part of BMW’s broader Physical AI strategy, which combines AI with physical robotic systems to expand automation beyond conventional industrial robots. Rather than replacing existing automation, humanoid robots are intended to complement it by handling monotonous, ergonomically challenging, or safety-critical tasks while allowing employees to focus on higher-value work.

According to the German firm, the project also leverages its expanding digital manufacturing ecosystem under its BMW iFACTORY strategy. Before production begins, engineers use the BMW Virtual Factory to simulate assembly processes in 3D, optimize workflows, and analyze worker movements to improve ergonomics and efficiency.

AI also plays a growing role in quality control through BMW’s AIQX (Artificial Intelligence Quality Next) platform. Using cameras, sensors, and AI-powered visual and acoustic inspection, the system continuously monitors production quality and provides real-time feedback to line workers through smart devices. BMW has standardized AIQX across its manufacturing operations and is evaluating extending the technology to suppliers, further integrating AI throughout its production network.

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