Spartanburg plant takes it to the next level with new humanoid Figure 03
SPARTANBURG, USA – The automotive industry is taking giant steps towards a new era of manufacturing, and the BMW Group is at the forefront of this transformation. The German automaker has announced the expansion of the use of humanoid robots based on artificial intelligence at its Spartanburg, USA plant. After a successful pilot project, the famous American factory is preparing to receive an improved and much more capable version of the technology: the Figure 03 robot.
The success that started it all: The Figure 02 Legacy
This transition is not coming out of nowhere. Last year, in 2025, BMW intensively tested the integration of the Figure 02 robot (developed in collaboration with Figure AI). The results exceeded expectations: in just 10 months, the humanoid robot actively supported the production of more than 30,000 BMW X3s.
Its mission was not an easy one. Figure 02 was responsible for feeding sheet metal parts into the welding process – a physically demanding task for human operators, requiring millimetre-precise precision and constant speed. The experiment demonstrated that the technology is mature and ready for the next step.
Figure 03: Safer, more precise and always “on duty”
The new generation, Figure 03, brings major improvements in construction and functionality, specifically designed to optimize workflow and protect human employees:
- Increased safety: The robot is made of soft components, drastically reducing the risk of injury in the event of direct interaction with factory personnel.
- Maximum availability: Thanks to the wireless charging system, Figure 03 can operate for much longer periods without prolonged technical breaks.
- Two-way communication: The robot is equipped with advanced audio features, allowing it to communicate vocally with surrounding teams.
- Digital tactile “sense”: The robot’s hands have been completely redesigned. They integrate high-sensitivity tactile sensors and video cameras mounted directly in the palms, providing surgical precision in manipulating and assembling new components.
From sorting to production line: A fully automated logistics flow
Figure 03's work is not limited to just rough assembly. The robot runs an advanced sequencing application that allows it to handle complex logistical tasks.
How does the process work?
- Figure 03 picks up large containers of unsorted parts.
- Identify and sort components into special sequencing carts.
- The full cart is automatically transported to a collection point.
- From there, the parts are picked up by an automated tow train or a Smart Transport Robot (STR) and delivered directly to the employee's workstation.
Hall 52: The technology hub ready for the electric future
All of this technological deployment will take place in Hall 52 of the Spartanburg plant. The space has already been expanded and massively modernized to accommodate the new automated production lines.
Currently, the popular BMW X3 SUV is assembled here, but the modernization of the hall also prepares the ground for an extremely important premiere: the production of the future BMW iX5 electric model.
Artificial Intelligence not only assembles, but also verifies: The AIQX System
For BMW, speed and automation mean nothing without impeccable quality. For this reason, in addition to humanoid robots, the German group relies on the AIQX (Artificial Intelligence Quality Next) system for quality control.
Using high-performance video cameras and dedicated sensors, AIQX performs real-time visual and acoustic inspections on the production line. If the system detects the slightest anomaly, it sends instant feedback to the smart devices (smartwatches or tablets) of employees on the line, ensuring that no car leaves the factory without meeting the brand's strict standards.
With this expansion, BMW is demonstrating that the use of humanoid robots is no longer a science fiction experiment, but a profitable industrial reality, capable of taking on repetitive and heavy tasks, leaving supervision and complex decisions in the hands of human experts.