Humanoid Robots in Plastics Processing – Innovation with Potential
25.06.2025
According to a recent market study by Nexery, around 20 million humanoid robots could be in use worldwide by 2030. These human-like machines open up new opportunities, especially for plastics processing companies: They are flexible in use, do not require fixed programming and can also be integrated into existing plants ('brownfield').
Repetitive and physically demanding tasks such as loading machines, internal transport or quality control are particularly suitable areas of application. At the same time, they can alleviate the shortage of skilled workers – a challenge that particularly affects medium-sized plastics processors.
Humanoid robots in industry: Use cases
The development of humanoid robots is progressing rapidly. The first models are already in use in pilot applications – including in the plastics industry. A look at four current solutions:
'Apollo' from Apptronik
The humanoid robot Apollo from the US manufacturer Apptronik was developed specifically for industrial use and is being tested in production at Mercedes-Benz, among others. Apollo has a modular design, can lift loads, operate machines and move autonomously within a space. Thanks to AI support, it adapts flexibly to different working environments.
'Figure 01' from Figure AI
With its Figure 01 model, Figure AI has developed a humanoid robot that has already been tested at BMW's Spartanburg plant in the US for use in car body construction. It can operate with both hands, perform complex gripping movements and is currently being used by its first commercial customers in real production environments. This makes Figure one of the pioneers in the industrial use of humanoid robots.
'Iggy Rob' from igus
With Iggy Rob, Cologne-based motion plastics specialist igus is launching a cost-effective, partially humanoid robot for industrial use. The robot does not have legs and moves on a stable, wheel-driven platform. Among other things, it can be used to insert components into injection moulding machines.
'The world is made for humans, so the potential for humanoid robots is huge,' explains Alexander Mühlens, Head of Low-Cost Automation at igus.
Iggy Rob is available at a starting price of €47,999, making it significantly cheaper than many comparable humanoid systems.
'Digit' from Agility Robotics
The humanoid robot Digit from Agility Robotics is being tested in pilot projects at automotive supplier Schaeffler. In plastics processing, for example, it can be used to load and unload injection moulding machines. The long-term goal is to integrate humanoid robots into the global factory network. The focus here is on flexibility: through the use of artificial intelligence, humanoid robots can respond to changing tasks and move autonomously in the production environment.
Study: Industry Expects Humanoid Robots to Be in Use in 3–10 Years
According to a study by Fraunhofer IPA with over 100 respondents, many companies see humanoid robots as a realistic option in industry – especially in the areas of material transport, order picking and machine operation. 74% of respondents expect them to be in use within the next three to ten years.
Just a few years ago, humanoid robots were primarily the stuff of films. Today, they can be found in the machinery of medium-sized companies.
Many parts of humanoid robots are themselves made of high-performance plastic components.
The 4NE-1 humanoid robot from NEURA Robotics weighs around 60 kg and is 170 cm tall.
Challenges: Costs, Safety, Acceptance
Despite all the progress made, challenges remain for the use of humanoid robots:
- Investment costs of up to €100,000 are currently still a barrier to entry – even though prices are falling.
- Functional safety and acceptance by the workforce are also key issues.
- Especially for SMEs, ease of use and integration without complex programming is crucial.
Outlook: A Topic for Tomorrow's Strategies
The technology is still in its infancy – but it is developing rapidly. Initial pilot projects show significant increases in efficiency and quality. Those who test early can secure advantages in the medium term. According to Nexery, the ROI is around 100% in the medium term.
For innovation-driven companies, now is the time to gain initial experience in order to be one step ahead tomorrow.
Author: Elena Blume | K-Mag
Elena Blume has been writing for various industry magazines for eight years and joined the K-Mag editorial team in 2021. She is particularly interested in topics related to innovative plastics solutions that contribute to sustainability and address current challenges relevant to industry and society.
At a glance
Humanoid robots are conquering the plastics processing industry: they take on flexible, stressful tasks and could become the production standard in just a few years. Large companies and SMEs are already testing the first applications.