The Tool Desk
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None should be treated as a universally deployable, off-the-shelf replacement for industrial robots. The evidence is still site-specific and pilot-oriented, so the right choice depends on the task, cell design, safety case, integration work and the vendor’s ability to prove sustained performance at your plant.
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Which humanoid robots have actually worked in factories?
Public primary-source evidence identifies three platforms with credible automotive-factory deployments or scheduled pilots:
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- Figure 02 from Figure AI: demonstrated in BMW’s Plant Spartanburg body shop and later used in a quantified 2025 production deployment.
- Apollo from Apptronik: tested at the Mercedes-Benz Berlin-Marienfelde Digital Factory Campus for material delivery, assembly-kit handling and initial quality checks.
- AEON from Hexagon Robotics: selected for BMW’s Leipzig work on high-voltage battery assembly and component manufacturing, with staged tests leading to a planned summer 2026 pilot.
These examples show that humanoids can be evaluated in real production environments, but they do not establish identical capabilities, guaranteed uptime or broad commercial availability. Each trial addresses a particular workflow and plant layout.
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Figure 02: the most quantified production demonstration
What BMW tested
BMW’s 11 September 2024 report describes Figure 02 working at Plant Spartanburg in a real body-shop environment. The robot inserted sheet-metal parts into special fixtures, a task that requires repeatable positioning before welding. BMW listed a mass of 70 kilogrammes, a height of approximately 170 centimetres and a 20-kilogramme load capacity. Compared with its predecessor, Figure 02 was reported to have three times the computing power, improved voice communication, a stronger battery and 16 active degrees of freedom per hand.
Those specifications describe the evaluated configuration, not a universal rating for every future software or end-effector package. A factory should therefore request the payload and reach envelope for the exact proposed tool and motion profile.
What the 2025 deployment measured
BMW’s later production report provides the clearest public operating data for any of the three platforms. During a 2025 Spartanburg deployment, Figure 02:
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- moved more than 90,000 components;
- covered approximately 1.2 million steps;
- operated for around 1,250 hours;
- worked ten-hour shifts from Monday through Friday.
The specific job was precise removal and positioning of sheet-metal parts for welding. BMW said the pilot demonstrated millimetre-level positioning for repetitive work. It also reported that production IT, occupational safety, process management and shop-floor logistics needed to be involved early, which is a useful warning against treating a humanoid installation as a simple equipment purchase.
Where Figure 02 fits best
Figure 02 is the strongest candidate when the target operation combines human-scale access with repetitive handling and precise placement, particularly in body-shop or fixture-loading work. Its public evidence is still one plant and one principal task; the Spartanburg figures do not prove performance in battery assembly, high-speed picking or every automotive line.
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Apollo: Mercedes-Benz’s intralogistics and inspection approach
What the Mercedes-Benz pilot covers
On 18 March 2025, Mercedes-Benz said it was testing Apollo at the Berlin-Marienfelde Digital Factory Campus. The initial uses are deliberately practical: transporting components or modules to the line, delivering assembly kits and performing initial quality checks. Apollo collected production data for defined MO360 use cases rather than being presented as a general-purpose autonomous worker.
Mercedes-Benz employees transferred production knowledge through teleoperation and augmented reality. The stated next step was autonomous operation, so the public description confirms a learning and validation phase rather than a claim of fully independent production at the time of the announcement.
Physical capability and handling model
Apptronik’s 15 March 2024 commercial-agreement announcement describes Apollo as approximately 5 feet 8 inches tall and 160 pounds, with a 55-pound lift capability. It also describes force control intended to support safe operation around people. The announced work included delivery of totes containing kitted parts, assembly-kit logistics, component inspection and movement of materials to the line.
The 55-pound figure is Apollo’s cited lift capability; it should not be interpreted as a safe payload for every reach, speed, gripper or walking condition. A buyer should ask for the derated payload at the planned reach, acceleration and floor conditions, together with recovery behavior when a tote is misplaced.
Where Apollo fits best
Apollo is the most directly documented option for intralogistics-oriented work: replenishing stations, moving modules and presenting kits so skilled employees can spend more time on higher-value assembly. Inspection is also in scope, but the available announcements do not publish defect-detection accuracy, intervention rates or production uptime. Apptronik called the Mercedes-Benz agreement Apollo’s first publicly announced commercial deployment, which indicates commercial engagement while still leaving the scale and contract terms unspecified.
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AEON: an emerging platform for batteries and components
BMW’s Leipzig plan
BMW says AEON was presented in June 2025 and had an initial test deployment at Plant Leipzig in December 2025. Another test was scheduled for April 2026, followed by a planned pilot in summer 2026. The announced work covers high-voltage battery assembly and component manufacturing, including parts for exterior applications.
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Because BMW describes a schedule rather than publishing results from the planned summer pilot, AEON should be considered an emerging candidate rather than a platform with the same production record as Figure 02.
Tool flexibility and mobility
BMW describes AEON’s human-like body as supporting interchangeable hands, grippers and scanning tools. The platform is also described as dynamically usable on wheels. That combination could matter in plants where one machine must move between stations or switch between manipulation and scanning, but the public material does not state payload, cycle time, battery endurance, accuracy, uptime or safety-validation results.
Where AEON fits best
AEON is worth evaluating when the business case depends on multifunctional work across battery and component areas rather than one fixed pick-and-place operation. Any evaluation should make the vendor demonstrate tool changes, wheel or drive behavior, access to the intended cell and the safeguards for high-voltage environments.
Figure 02, Apollo and AEON compared
| Platform | Documented site and timing | Publicly described work | Published physical data | Evidence maturity |
|---|---|---|---|---|
| Figure 02 | BMW Plant Spartanburg; 2024 test and quantified 2025 deployment | Sheet-metal removal and positioning in body-shop fixtures for welding | 70 kg; approximately 170 cm; 20 kg load capacity; 16 active degrees of freedom per hand | Strongest public production metrics, but one plant and a defined task |
| Apollo | Mercedes-Benz Berlin-Marienfelde Digital Factory Campus; testing reported in March 2025 | Intralogistics, assembly-kit and tote delivery, module transport and initial quality checks | Approximately 5 ft 8 in; 160 lb; 55 lb lift capability; force control described | Commercial pilot with teleoperation and augmented-reality knowledge transfer; autonomous step announced, results not published |
| AEON | BMW Plant Leipzig; presented June 2025, test in December 2025, further test scheduled April 2026 and pilot planned for summer 2026 | High-voltage battery assembly and component manufacturing | Payload, dimensions, cycle time and endurance not stated in the cited announcements | Early staged evaluation; public pilot results not yet established |
The table is a decision aid, not a universal ranking. A robot with less public data may still fit a particular station better, while a strong demonstration may fail when the floor, fixtures, takt time or safety requirements change.
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Which is the best humanoid robot for automotive manufacturing?
There is no single best platform for every automotive department. For a body-shop operation that resembles BMW’s sheet-metal fixture task, Figure 02 currently has the most relevant public evidence and the only detailed production counts among these three. For line-side replenishment, kit presentation and tote movement, Apollo’s Mercedes-Benz use case is the closest match. For a planned multifunctional program spanning battery and component work, AEON is the platform BMW is evaluating, but its public maturity is earlier.
Make the selection at task level rather than by brand or humanoid appearance. A useful demonstration should use your part, fixture, container, scanner, floor markings, takt target and exception cases. Require the vendor to show the same operation after a dropped part, an obstructed path, a changed component orientation and a safe stop.
Independent reader supportYour contribution helps us test, update, and keep practical guides available for everyone.A factory buyer’s evaluation framework
1. Define the task and its constraints
Document payload at the wrist, reach, grasp points, presentation height, cycle time, walking distance, floor transitions, lighting, temperature, part tolerances and the percentage of work that is repetitive. Separate sheet-metal positioning, kitting, tote movement, inspection, battery assembly and component work; they impose different mechanical and software requirements.
2. Verify dexterity, payload and tooling
- Request rated and derated payloads at the actual reach and speed.
- Check hand degrees of freedom, grip force, compliance and force-control limits.
- List available grippers, scanners and custom end effectors, including changeover time.
- Measure whether the robot can reach the fixture without collisions or awkward wrist orientations.
Figure 02’s cited 20-kilogramme load capacity and 16 active degrees of freedom per hand, and Apollo’s cited 55-pound lift capability, are useful starting points but not substitutes for a task trial.
3. Build the human-safety case
Review force and speed limits, emergency-stop behavior, safe-state recovery, obstacle detection, guarding, restricted zones and restart procedures. Include the exact gripper and payload in the risk assessment. Train operators and maintenance staff on intervention, lockout and recovery; a humanoid that shares aisles with people creates different hazards from a fenced industrial arm.
4. Separate teleoperation from autonomy
Ask how often a person must intervene, what events trigger teleoperation, how long recovery takes and whether interventions are logged by task, shift and cause. Mercedes-Benz’s Apollo program explicitly used teleoperation and augmented reality to transfer production knowledge before autonomous operation. Treat autonomous performance as a measurable acceptance criterion, not an assumption based on a demonstration.
5. Plan integration before delivery
Connect the project to manufacturing execution, production IT, logistics, quality and occupational-safety teams. BMW describes a qualification path that moves from theoretical assessment to laboratory evaluation, real-world test deployment and pilot. Use equivalent gates: simulation and interface review, controlled lab test, production-floor trial, then a limited pilot with predefined exit criteria.
6. Demand sustained-operation data
Request site-specific hours, shifts, uptime, mean time between interventions, throughput, quality results, recovery time and maintenance events. BMW’s Figure 02 report is unusually quantitative, but it remains evidence from one deployment. Ask whether reported hours include supervised testing, paused time, teleoperation and engineering support.
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Confirm whether the proposal is a purchase, lease or robotics-as-a-service arrangement. Put support hours, spare parts, software updates, cybersecurity responsibilities, data ownership, integration fees, training, acceptance testing and termination rights in writing. The cited public announcements do not publish prices or standard contract terms, so a buyer must obtain those directly from the vendor or authorized integrator.
Are humanoid robots commercially available or still in pilots?
They are commercially engaged but not proven as interchangeable, mass-deployable factory products. Apptronik and Mercedes-Benz announced a commercial agreement, yet Mercedes-Benz described the Berlin work as testing and a progression from teleoperation toward autonomy. BMW reported a real Figure 02 production deployment, while its AEON announcement laid out staged tests and a planned pilot. Those facts support serious procurement discussions and paid pilots, not a conclusion that any of the three can be installed across a factory without engineering qualification.
Public sources also do not establish universal production availability, cross-site reliability, total cost of ownership or independent safety benchmarks. A plant should treat each deployment as a site-specific automation project with a measurable business case.
Common mistakes and how to avoid them
- Choosing by headline payload: lift ratings vary with reach, speed, grip and balance. Test the complete motion.
- Assuming a pilot proves general capability: Figure 02’s results concern one body-shop task; Apollo’s announcements concern logistics and inspection; AEON’s public evidence is still scheduled evaluation.
- Ignoring intervention work: count teleoperator actions, resets, part presentation and blocked-path recovery in the labor model.
- Leaving safety until installation: involve safety and workers early, before fixtures and traffic routes are fixed.
- Comparing robots without comparing workflows: a mobile kit-delivery task and a millimetre-precise welding preparation task need different acceptance tests.
- Assuming published dimensions equal available clearance: model the robot, payload, tool, cable routing and human escape paths together.
Practical shortlist by factory use case
| Use case | Most relevant platform to investigate first | Why | Evidence caveat |
|---|---|---|---|
| Body-shop sheet-metal positioning | Figure 02 | BMW reported a real fixture-loading task and quantified 2025 operation | One plant, one principal task and no universal uptime guarantee |
| Line-side delivery and kitting | Apollo | Mercedes-Benz explicitly described module transport, assembly kits and totes | Public program included teleoperation; autonomous performance figures are not published |
| Initial component inspection | Apollo | Inspection is part of the announced Mercedes-Benz scope | No public accuracy or defect-recall metrics in the cited announcement |
| Battery and multifunctional component work | AEON | BMW’s Leipzig program targets high-voltage battery assembly and component manufacturing with interchangeable tools | Public pilot results and core performance specifications are not stated |
Bottom line for an automation project
Start with the process, not the humanoid label. Figure 02 is the most evidence-backed choice for a BMW-like sheet-metal handling task; Apollo is the clearest fit for Mercedes-Benz-style intralogistics and inspection; AEON is a promising but earlier-stage option for battery and component applications. Run a controlled, site-specific pilot, publish intervention and quality data internally, and expand only after the robot meets safety, throughput and maintenance criteria under normal and failure conditions.
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