At the Spartanburg plant, Figure 03 will sort unsorted components from large containers into sequencing trolleys. Automated vehicles will then deliver the parts to assembly lines in the required production order, a common process in automotive manufacturing that BMW said could be expanded to other logistics operations.
BMW said humanoid robots are intended to complement existing automation by taking on repetitive, physically demanding and safety-critical tasks, allowing employees to focus on higher-value work while improving workplace safety.
The deployment follows an 11-month pilot of Figure AI’s Figure 02 robot, which BMW said demonstrated that humanoid robots can perform complex manufacturing tasks in real production environments.
“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,” Brett Adcock, founder and CEO of Figure AI, said in a press release last week.
FigureAI’s humanoid robots deployed at BMW’s Spartanburg plant in the U.S. Video courtesy of FigureAI
BMW said Figure 02 supported production of more than 30,000 BMW X3 vehicles over 10 months. In the body shop, the robot inserted sheet-metal parts for welding, a task requiring high speed and precision that can also be physically demanding.
Adcock said the experience gained from the pilot laid the groundwork for deploying the successor model, Figure 03.
Figure 03 features hardware and software upgrades designed for broader manufacturing use, including softer exterior components to improve workplace safety, wireless charging to reduce downtime, speech-to-speech communication, and redesigned hands with tactile sensors and palm cameras for more precise handling of parts.
The automaker is also preparing its first European deployment of Physical AI at its Leipzig plant in Germany, where humanoid robots will be integrated into vehicle production, according to Interesting Engineering.
The initiative is part of BMW’s broader Physical AI strategy, which combines artificial intelligence with robotic systems to expand automation beyond conventional industrial robots. Rather than replacing existing automation, the company aims to use humanoid robots to perform tasks that are repetitive, ergonomically challenging or hazardous while supporting human workers.
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