How Humanoid Robots Have Entered the Industrial Mainstream

Capable of walking through factories, using tools and handling tasks that traditional fixed industrial robots cannot perform, humanoid robots have transformed how companies approach automation. 

Instead of rebuilding production lines around stationary robots, manufacturers can place humanoid machines into their existing operations: particularly useful for companies dealing with worker shortages, particularly in regions where manufacturing faces rising labour costs.

According to Hexagon’s ‘Future of Robotics 2035’ report, the technology centres on collaboration rather than replacement. Interviewing executives from Nvidia, Turner Construction and other companies, the report found that 82% of organisations increased automation investments in the past year.

“This report clearly indicates that the future isn’t going to be a clash of robot vs. human. It’s going to be about robots working with humans,” says Burkhard Boeckem, Chief Technology Officer at Hexagon. “We believe the most resilient and competitive organisations will be those that treat autonomy as a scaffold for human potential, not a replacement for it.”

Integration problems remain despite technology advances

However despite their promise, the deployment of humanoid robots continues to pose difficulties for many companies. Hexagon’s research shows 41% of organisations have trouble integrating humanoid robots with their existing manufacturing systems, with problems including connecting new robots with older control systems, safety equipment and production software.

The integration challenge reflects broader digitisation problems across manufacturing. Many facilities operate with a mix of equipment from different eras, creating complex technical environments that resist simple automation solutions. Humanoid robots must navigate not only physical spaces but also communicate with various systems that may use different protocols and standards.

However, companies that prioritise human factors alongside technical considerations achieve better outcomes. When manufacturers involve workers in deployment planning and maintain transparent communication about robot capabilities and limitations, employee acceptance improves significantly. This approach often leads to unexpected benefits, with workers becoming advocates for the technology rather than obstacles to implementation.

As this suggests, achieving buy-in from workers is important for successful implementation. “Humans are adaptive, creative, and makers that are not replaceable cogs for output-driven AI,” says Dr Juliet Aiken, Organisational Psychologist at Conducere + Volta, who contributed to Hexagon’s report. “This report reflects on where human strengths surpass automation and outlines the workforce implications from multiple angles to create a rich landscape of the future: one supported by AI where humanoid-robotics enhance work but don’t replace us.”

Hexagon launches AEON robot for industrial uses

Hexagon released AEON, a humanoid robot, in June 2025 to address worker shortages in industrial settings. The robot uses Hexagon’s sensor technology with AI-controlled movement systems. It includes battery swapping that allows operation without stopping for charges.

AEON incorporates several technological advances that address common industrial requirements. The robot combines Hexagon's sensor technology with AI-controlled movement systems, allowing it to navigate factory floors while performing precise tasks. A battery swapping mechanism enables continuous operation across multiple shifts without downtime for charging, addressing a key limitation of battery-powered industrial equipment.

Ola Rollén, Chairman of the Board at Hexagon, positions the development within the company's broader technology strategy. “Hexagon’s legacy in precision measurement and sensor technologies has always been about enabling next-generation autonomy,” he explains. “Hexagon is one of the best-placed companies in the world to lead and shape the field of humanoid robotics.”

The robot's capabilities are being tested in real production environments through partnerships with established manufacturers. Schaeffler, a German automotive and industrial supplier, and Pilatus, a Swiss aircraft manufacturer, are conducting trials that cover object handling, machine operation, component inspection and reality capture applications.

The business case for humanoid robotics becomes particularly compelling in high-cost manufacturing regions where labour shortages and rising wages threaten competitiveness. Roman Emmenegger, VP Manufacturing at Pilatus, views AEON as addressing fundamental challenges facing Swiss manufacturing. “Facing today’s challenges of manufacturing in Switzerland, we believe that AEON will become a contributing solution in sustaining our competitiveness in more than ever tougher global markets,” he explains.

At Schaeffler, humanoid robots fit within the company’s broader technology transformation plans. Sebastian Jonas, Senior Vice President Advanced Production Technology, positions the technology strategically: “By leveraging disruptive technologies such as humanoid robots, Schaeffler paves the way to becoming the leading motion technology company.”

Having launched in June, Hexagon is planning an expansion of its AEON deployment following initial tests. “With AEON, we’re advancing physical AI to tackle real operational challenges – bridging cutting-edge technology with practical industry needs,” says Arnaud Robert, President of Hexagon’s Robotics division. “Over the next six months we’ll be deploying AEON in production environments before expanding our commercial rollout.”