In the ever-evolving landscape of automotive manufacturing, a transformative shift is underway. 2025 has been widely recognized as the “mass production year” (year of mass production) for humanoid robots, marking a pivotal transition from technical validation to large-scale industrial application. As core technologies achieve breakthroughs and production processes accelerate, humanoid robots are emerging as the next frontier in factory automation, with major automotive players leading the charge. This article delves into the current advancements, real-world applications, market potentials, and challenges of humanoid robots in the automotive industry, shedding light on their role in reshaping global manufacturing.
The Rise of Humanoid Robots in Automotive Manufacturing
The automotive sector has long been a pioneer in adopting automation, from industrial robots to collaborative machines. Now, humanoid robots are taking center stage. Their ability to mimic human movements and adapt to structured yet dynamic factory environments makes them ideal for tasks that have traditionally required human dexterity, such as assembling intricate components, quality inspection, and material handling.
Global Automakers Embrace Humanoid Automation
Leading the charge, Hyundai Motor Group recently announced plans to deploy Boston Dynamics’ Atlas humanoid robots at its new factory in Georgia, USA. As part of a $21 billion investment in the U.S., these robots will participate in various production stages, aiming to boost efficiency and achieve an annual output of 300,000 electric and hybrid vehicles. Atlas, with its human-like mobility and adaptability to complex environments, represents a leap forward in full-process factory automation.
Tesla, too, is making waves with its in-house developed Optimus. CEO Elon Musk revealed that Optimus is expected to perform real tasks in Tesla factories by the end of 2025, with commercial sales planned for 2025. Meanwhile, BMW partnered with Figure AI in early 2024 to test the Figure 01 and Figure 02 robots at its Spartanburg plant. The Figure 02, equipped with OpenAI’s large language model, demonstrates enhanced cognitive capabilities, suitable for warehouse, logistics, and retail applications.
China’s Growing Involvement
In China, automakers are rapidly joining the humanoid robot race. In February 2025, Xiaomi’s CyberOne robot began phased deployment at its Beijing Yizhuang Smart Factory, with plans to exceed 2,000 units by 2026. XPeng’s IRON robot is already being used in production and aims to expand into sales outlets and offices. GAC Group unveiled its third-generation GoMate robot in December 2024, which will soon enter its production lines for inspection and sorting tasks.
Other collaborations include SAIC Audi’s trial of UBTECH’s Walker S1 for air conditioning pipe leak detection and Dongfeng Liuzhou’s plan to deploy 20 Walker S1 units in the first half of 2025 to enhance automation. UBTECH has also partnered with BYD, Geely, and Foxconn, signaling a broad-based adoption across China’s automotive supply chain.
Great Wall Motors’ strategic alliance with Unitree Robotics in April 2025 focuses on embodied intelligence and “vehicle-robot” scenario innovation, further integrating robotics with automotive manufacturing.
Market Projections and Industry Impact
According to IDTechEx’s report Humanoid Robots 2025–2035: Technology, Market, and Opportunities, the automotive industry will deploy approximately 1.6 million humanoid robots by 2035. This surge is driven by three key factors: technological progress, cost reduction, and policy support.
Advantages of Humanoid Robots in Factories
- Adaptability to Existing Infrastructure: Unlike traditional industrial robots that require retooling, humanoid robots can operate in standard factory environments without major layout changes, reducing upfront investment.
- Task Versatility: From quality inspection to parts assembly, humanoid robots excel in tasks demanding precision and flexibility. For example, UBTECH’s Walker S series can inspect Audi RS5 tires in 60–80 seconds with over 99% accuracy. Mercedes-Benz’s Apollo robot, developed with Apptronik, handles 25 kg payloads for logistics and assembly tasks in Hungary.
- Safety and Labor Liberation: By taking on repetitive or hazardous tasks—such as detecting air conditioning refrigerant leaks (a task involving potential respiratory risks)—humanoid robots enhance worker safety and well-being.
Economic Drivers
Automakers are drawn to humanoid robots for their long-term cost-saving potential. IDTechEx predicts that the cost per humanoid robot could drop from over $100,000 today to around $20,000 in the future, thanks to economies of scale and shared supply chains (e.g., reuse of motors, lidar, and batteries from automotive technology). In the short term, they reduce labor costs in material handling and quality control; in the long term, they open new revenue streams through robotics-as-a-service in logistics and warehousing.
Technical and Commercial Hurdles
Despite the promise, humanoid robotics face significant challenges that must be overcome for widespread adoption.
Technical Limitations
- Battery Life: Most humanoid robots currently have a runtime of 2–6 hours. For instance, Unitree’s G1 lasts about 2 hours, while UBTECH’s Walker S2 achieves 4–6 hours. The industry standard for full-day operation is 8–10 hours, requiring breakthroughs in energy density and fast-charging technology.
- Payload Capacity: Existing robots typically handle 10–50 kg, falling short of automotive needs for 搬运 (搬运) 50–100 kg components like engine parts. Tesla’s Optimus and BMW’s Figure 01, both with 20 kg payloads, illustrate this gap.
- Autonomy in Complex Environments: Navigating dynamic factory floors and adapting to unexpected obstacles remains a challenge. Improvements in computer vision, sensor fusion, and AI-driven path planning are critical.
Commercial and Regulatory Barriers
- High Initial Costs: Current prices exceed $100,000 for most models, though Tesla aims to price Optimus below $30,000. Long payback periods and limited multi-scenario usability hinder small-scale adopters.
- Lack of Standardization and Regulations: Industrial-grade reliability certifications and safety protocols are still evolving. For example, there are no universal standards for robot-human interaction in factories, slowing commercialization.
IDTechEx notes that humanoid robots are currently in the testing and validation phase, akin to the early days of automated guided vehicles (AGVs). Over the next 5–10 years, they are expected to expand from automotive manufacturing to broader industrial applications.
The Road Ahead: Innovation and Integration
To unlock their full potential, humanoid robots require cross-industry collaboration. Automakers, robotics startups, and tech giants are partnering to address technical bottlenecks. For example, the integration of large language models (e.g., OpenAI in Figure 02) enhances robots’ ability to understand complex instructions, while advancements in embodied intelligence (e.g., Great Wall Motors’ partnership with Unitree) aim to improve adaptability.
Policy support will also play a role. Governments worldwide are investing in advanced manufacturing, with humanoid robotics often highlighted as a key technology for fostering new productive forces. As regulations mature and use cases multiply, humanoid robots are poised to redefine not just automotive factories but global industrial labor dynamics.
In conclusion, the automotive industry’s embrace of humanoid robots marks a historic shift toward smarter, more efficient manufacturing. While challenges persist, the momentum is undeniable. As 2025 unfolds, the cyber workers are ready to take their place on the factory floor, driving innovation and reshaping the future of work.