Foundries in transition: Why humanoid robots are now in demand

Amidst heat and precision, new hybrid working environments could emerge. Humanoid robots are more than just tools – they are co-creators of industrial evolution. The new Nexery Humanoid Robot Study 2025 shows why humanoid robots are now gaining relevance in foundries. Delve into the future of foundry technology – with this expert article by Tobias Bock, Managing Partner at Nexery.

Foundries in the midst of global upheaval

Industrial change in foundry technology is currently being driven by several factors simultaneously: a noticeable shortage of skilled workers, rising productivity demands, growing expectations regarding ergonomics and health and safety at work, and the need for processes that are both stable and flexible. Particularly in foundries, where heavy physical labour, high temperatures and frequently changing work tasks converge, traditional automation approaches are increasingly reaching their limits.

Traditional industrial robots are ideally suited to clearly structured, repetitive tasks. However, in environments with varying geometries, unstructured workflows or high thermal stress, their adaptability is limited. This is precisely where humanoid robots come in: with a human-like build, flexible gripping capabilities, AI-supported motion planning and significantly greater adaptability, they can take on tasks that until now could only be reliably carried out by human workers.

This does not mean that humanoid robots are intended to replace people. Rather, the aim is to ease the workload on existing staff, make workplaces more ergonomic and, at the same time, increase efficiency – without the need for costly modifications to existing production environments.

Technological foundation: systems ready for series production from 2025

Nexery’s Humanoid Robot Study 2025 shows: From this year onwards, the first market-ready humanoid systems will cross the threshold into industrial use. Leading suppliers such as Tesla, Apptronik, Neura Robotics and Agility Robotics are investing heavily in applications specifically tailored to production and logistics environments.

This new generation of robots combines several key technologies:

• a high degree of mobility thanks to advanced joint and drive systems, enabling complex handling tasks
• artificial intelligence for navigation and decision-making, enabling them to operate safely even in dynamic, unstructured environments
• safe human-robot collaboration thanks to sophisticated sensor technology and real-time collision avoidance
• modular, adaptable gripping systems that allow the handling of different workpieces and tools.

These features make humanoid robots a viable economic option for foundries for the first time – not merely as a technological gimmick, but as a productive addition to day-to-day operations.

Specific areas of application in foundries
According to the study, the greatest potential currently lies in two areas: intralogistics and quality assurance.

• In intralogistics, humanoid robots can handle the transport of materials between stations, prepare tools or sort components.
• In quality assurance, they are capable of carrying out visual inspections, detecting surface defects and classifying components accordingly.

In the medium term – as the technology matures – further tasks will become feasible: operating machinery, reworking castings, carrying out maintenance work on equipment or even assisting with set-up processes.

The most promising benefits are:

• reduction in physical strain on staff
• consistent process quality regardless of shift, individual performance on the day or staffing levels
• greater process stability, even with smaller batch sizes or varying orders.

Successful introduction to the technology

The study recommends a step-by-step approach to minimise risks and quickly demonstrate the benefits:

1. Assessment of ergonomically critical tasks and identification of potential areas of application
2. Evaluation of the potential for automation, taking into account technical, economic and organisational factors
3. Pilot of a clearly defined use case for testing under real-world conditions
4. Integration into routine operations and simultaneous development of internal expertise.

A clearly defined pilot process ensures that not only technological feasibility but also cost-effectiveness and operational acceptance can be assessed.

Action required for decision-makers
For foundry managers, this means:

• Start technology scouting now to identify relevant suppliers and solutions at an early stage
• Initiate and evaluate pilot projects
• Build up internal resources (engineering, IT, process management) in a targeted manner
• Review manufacturer contacts and explore opportunities for collaboration.

Those who get on board now will gain a competitive edge. In addition to short-term efficiency gains, this also creates a strategic opportunity to proactively meet future requirements – such as stricter health and safety regulations or rising quality standards.

Conclusion
Humanoid robotics marks a turning point in industrial automation. In foundry technology in particular, these systems fill gaps for which there were previously no economically viable solutions. They combine the flexibility of the human workforce with the advantages of machine precision and endurance.

Companies that engage with this technology now are not only securing their productivity but also their long-term competitiveness – in an industry where a willingness to innovate determines tomorrow’s success.

About the author:
Tobias Bock is Managing Partner at Nexery and an expert in technological strategies for industry. The full Humanoid Robot Study 2025 is available at www.nexery.de.