Humanoid robots are intelligent robotic systems designed to resemble the human form, capable of imitating human movements and behaviors. Typically, they feature bipedal walking, arm manipulation, head rotation, environmental perception, and voice interaction. As one of the most complex and challenging areas in robotics, humanoids represent the highest level of interdisciplinary integration across artificial intelligence, mechanical engineering, materials science, and control theory.
Structurally, humanoid robots consist of several core systems:
· Structural framework (skeleton, joints, casing)
· Actuation system (motors, reducers, actuators)
· Sensing system (vision, force, touch, balance)
· Control system (motion planning, decision algorithms)
· Power system (batteries, energy management)
Among these, the structural framework is critical—it serves as the physical backbone, directly influencing performance, cost, and reliability.
The application of humanoid robots continues to expand. They are being deployed in industrial assembly, logistics, and quality inspection, in services such as reception, guidance, and elder care, and in special environments like space exploration, disaster relief, and deep-sea operations. With advances in AI, humanoid robots are moving out of laboratories and into commercial applications, becoming a strategic focus for global technology competition.
2024 has been called the “first year of mass production” for humanoid robots. According to GGII, global shipments are expected to exceed 30,000 units in 2024—a year-on-year growth of over 60%. North America, Europe, and Asia-Pacific dominate, with companies like Tesla, Boston Dynamics, and BMW making significant investments, while China, Japan, and South Korea accelerate their own deployments.
China has quickly emerged as a key player. In late 2023, the Ministry of Industry and Information Technology (MIIT) issued a roadmap aiming for internationally advanced humanoid robot products by 2025 and a secure, world-class supply chain by 2027. Backed by policy and capital, companies like UBTECH, Unitree Robotics, and Fourier Intelligence have accelerated R&D, attracted financing, and even gone public.
By 2030, annual global sales of humanoid robots are projected to surpass 5 million units, with market size reaching hundreds of billions of dollars. Key growth areas will include industrial manufacturing, logistics, commercial services, and household companionship. At the same time, humanoid robots are trending toward greater intelligence, lightweight design, and human-like interaction.
Aluminum die casting has become central to robot design because of its lightweight, high-strength, and excellent thermal and electromagnetic properties. Key application areas include:
· Joint modules – housings for harmonic reducers, motor casings, and bearing seats, requiring high precision and heat dissipation.
· Skeleton structures – lightweight integrated castings reduce welding points, increase rigidity, and optimize strength-to-weight ratio.
· Protective shells – external casings offering EMI shielding, corrosion resistance, and heat management, while maintaining sleek design.
· Thermal management systems – high thermal conductivity aluminum alloys efficiently dissipate heat from chips, motors, and amplifiers.
· Specialized components – dexterous hands, robot feet, and sensor mounts, all benefiting from aluminum’s lightweight strength and design flexibility.
1. Lightweight yet strong – Aluminum density is one-third of steel but can achieve strength close to high-grade alloys, crucial for improving robot agility and energy efficiency.
2. Excellent process adaptability – Die casting enables complex designs with micron-level precision, high production efficiency, and material utilization over 90%.
3. Functional integration – Aluminum alloys offer high thermal conductivity, electrical conductivity, and EMI shielding, supporting structural and functional unification.
4. Cost-effectiveness and scalability – Compared with carbon fiber or titanium, aluminum offers much lower material and processing costs, with a mature, recyclable supply chain.
5. Opportunities and Challenges for Die Casting Manufacturers
Humanoid robots bring both opportunities and challenges for aluminum die casting suppliers:
· Opportunities: demand for high-performance alloys, integrated die casting, and cross-industry technology transfer (from EVs, aerospace, 3C electronics).
· Challenges: high technical thresholds, cost pressure during early commercialization, shortage of skilled talent, and intensifying competition.
To stay competitive, manufacturers must invest in materials R&D, process innovation, precision equipment, and collaborative partnerships with robot OEMs.
Humanoid robots mark a new era of intelligent manufacturing and material innovation. Aluminum die castings are at the heart of this revolution, balancing lightweight design, strength, thermal management, and cost efficiency.
The future will bring:
· Higher-performance alloys with greater strength and conductivity
· Integrated casting solutions to reduce parts and improve reliability
· Smart functional integration with embedded sensors and actuators
· Sustainable production with recycled and low-carbon aluminum
Industry forecasts suggest that by 2025, the global market for aluminum alloy components in humanoid robots will exceed 5 billion RMB, growing at a compound annual rate of over 60%. By 2030, with 5 million units expected in annual sales, demand for aluminum will skyrocket to over 100,000 tons.
For die casting companies, the winners will be those who can deliver lighter, stronger, and smarter custom aluminum die casting solutions, positioning themselves as indispensable partners in the humanoid robotics value chain.
EDT Diecasting Technology (Suzhou) Co., Ltd. is a trusted partner in this wave of humanoid robotics innovation. As an Italian-owned precision die casting manufacturer, EDT has a registered capital of €1.345 million, employs 120 staff, and operates a modern 9,000 m² facility in Suzhou High-Tech Zone.
Equipped with state-of-the-art hot and cold chamber die casting machines, multi-slide systems, vacuum die casting, and closed-loop controls, EDT specializes in high-quality zinc and aluminum die castings for automotive parts, hardware, electronics, telecommunications, and construction.
Certified under ISO9001 and IATF16949, the company has earned recognition as an Innovative SME and a Technology-based SME in Suzhou, holding 21 patents to date.
In the emerging humanoid robotics sector, EDT leverages its expertise in precision die casting, mold development, and materials engineering to deliver lightweight, high-strength, and complex aluminum alloy components. With full-process capabilities from material development to machining and testing, EDT is ready to support global partners in building the next generation of humanoid robots.
Hotline
0512-67371602
E-mail：sales@edt-china.cn
Add：West Building, 66 Songshan Road, Suzhou New District, P.R. China
Hotline
