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Autonomous systems & Physical AI

Physical AI: from prototype to measurable value

Now is the moment that decides who leads in autonomous systems.

in market potential the Physical AI ecosystem could unlock by 2035.

McKinsey

robots are at work in factories worldwide. The annual growth rate is around 10%.

IFR

4,28 Mio.

robots per 10,000 employees. That puts Switzerland in the global top 10.

IFR 

294
Engineers in a modern laboratory discussing prototype

Autonomous systems are evolving fast, as different technologies converge: mature sensors, fast local signal processing, and powerful small language models.

So the challenge lies less and less in the technology, and more in scaling. What convinces as a prototype has to work reliably in everyday operations too.

Whether you develop such systems or want to deploy them in your organisation: here you'll find perspectives, practical examples, and answers to your implementation questions. Find out what matters on the way to a scalable market and reliable operation of autonomous systems, and how Zühlke supports you along that way.

The two questions that decide autonomous systems

Every successful deployment of autonomous systems asks manufacturers and users to answer two essential questions: what does the system need to perceive? And how much autonomy does it get?

What does the system need to perceive?

An autonomous system can only decide as well as it perceives and understands its environment. What convinces in a demo has to work in operations too. Real operating conditions show whether the prototype becomes a reliable product that delivers the value you expect.

  • Measure: cameras, lidar, and other sensors capture the environment. Sensor fusion merges their data into one reliable picture in real time, even in dust, backlight, or vibration.
  • Understand: a model interprets the data and makes sense of the situation: what's there, what has changed since the baseline, and what does that mean for the mission?
  • Decide: from that understanding the system derives a predefined or a possible action. The action stays within clearly defined limits.
  • Stay traceable: your team has to be able to check at any time when and why the system makes a decision. That's the decisive point for keeping the system safe, and it matters for certification too.

For manufacturers, the quality of perception decides whether the product succeeds. Our experts in optical systems, sensor fusion, and AI models strengthen development teams, or take on component development entirely.
Users should start right here when they compare suppliers. We advise vendor-neutrally on which sensor setup makes most sense in your particular production environment.

How much autonomy?

Not every system needs full autonomy. What counts is which tasks it takes on itself, and when a person steps in. The right level of autonomy depends on risk, on economics, and on regulatory requirements, not on what's technically possible alone.

  • Human-in-the-loop: the system suggests, the person approves every action. That makes sense when mistakes are expensive or can't be undone.
  • Human-on-the-loop: the system acts, the person monitors and intervenes in exceptional cases. This way you can handle many processes without giving up human oversight.
  • Human-out-of-the-loop: the system acts independently within clear limits. People set the goals and the guard rails.
    Economics: you can only scale operations once one person monitors several systems rather than just one. The level of autonomy therefore determines your business case.

We assess the use case, the risks, and the regulatory requirements with you. From that we derive how independently a system may act, and where people have to stay involved. The goal is a system you can run responsibly and economically, and that meets the requirements for certification.
 

Perspectives on autonomous systems

Whether you develop or deploy autonomous systems, our articles offer perspectives, practical know-how, and concrete answers for the journey from prototype to reliable operation.

When products become systems: new paths in development

Hardware, software, data, and AI have to work together from the start. Five priorities show what matters when you develop cyber-physical systems.

Read the blog post

Connected systems: why your experience makes the difference

You know your products and how your customers work. Read how you can combine that knowledge with software and data, and turn it into a competitive advantage.

Read the blog post

From product to system: why digital extras aren't enough

More digital features don't make a better product. What counts is the value in use. Read what that means for your strategy, your organisation, and your culture.

Read the blog post

AI in industry: where it pays off

Which tasks can AI take on in your organisation? Discover concrete use cases along the industrial value chain, and the value they create in practice.

Read the blog post
Industrial new factory & modern machines

Benchmark study

Where do you stand in industrial product development?

Our benchmark with 55 industrial companies from the DACH region shows how far established companies really are, and what the front-runners do differently.

Read the study

Autonomous systems in practice

From inspection robots and AI-driven plants to smart software: see how we've helped our clients take autonomous systems from prototype to reliable operation.

MARTIN GmbH: more efficient waste incineration thanks to computer vision

Real-time video images detect the fire position on the grate, and an AI model determines the adjustment needed. That way a thermal waste treatment plant burns more evenly and more efficiently.

Read the case study
Martin waste incineration furnace with active combustion chamber and burning material

AOT: the surgical robot CARLO learns to see

Optical coherence tomography and machine learning let CARLO recognise bone precisely. A validated data platform paves the way to FDA approval.

Read the case study

Hexagon opens up new markets with Aura

Hexagon and Zühlke combine their expertise from optics to AI. Together they take the Aura 3D Imaging System for aesthetic medicine from the lab to the market.

Read the case study
Close-up of the Hexagon Aura sensor unit, showing its array of cameras, lights, and a green LED indicator strip, with the Hexagon logo overlaid.

Bystronic relieves employees of manual work with a Robot Manager

With the Robot Manager developed by Zühlke, employees program and simulate bending sequences offline in 3D. Robots then take on the manual work, efficiently and safely.

Read the case study
Two colleagues in business attire consulting with a technician in a manufacturing facility, next to the Bystronic logo.

“Zühlke integrated seamlessly into our team and contributed its strong multidisciplinary expertise to deliver a business-critical project in just twelve months, significantly faster than usual and without compromising on quality.”

Luca Rabezzana
Luca Rabezzana

Project Leader, Sensirion Connected Solutions AG

“Working with Zühlke is an extraordinary transformation journey. The solutions we've developed together not only result in a massive reduction of CO2 emissions but also promise significant operational savings.”

portrait photo of Christoph Rüttimann, CTO of Bystronic Group
Christoph Rüttimann

CTO Bystronic Group

“Instead of having to carry out the tedious bending task manually, I can now easily generate and simulate the desired automation steps in 3D and command the robot to perform the bending operation.”

Ueli Gasser Bystronic
Ueli Gasser

Application Technician Bending

“The Zühlke development phase was characterised by rapid execution, with agile methodologies applied to both software and hardware, enabling continuous iteration and swift adaptation to market-driven insights throughout the development process.”

Gemma Taverni
Gemma Taverni

Director R&D, Hexagon

“Zühlke integrated seamlessly into our team and contributed its strong multidisciplinary expertise to deliver a business-critical project in just twelve months, significantly faster than usual and without compromising on quality.”

Luca Rabezzana
Luca Rabezzana

Project Leader, Sensirion Connected Solutions AG

“Working with Zühlke is an extraordinary transformation journey. The solutions we've developed together not only result in a massive reduction of CO2 emissions but also promise significant operational savings.”

portrait photo of Christoph Rüttimann, CTO of Bystronic Group
Christoph Rüttimann

CTO Bystronic Group

Female design professional checking 3D drone in industry

Whether it's autonomous machines, drones, AI-controlled plants, or robots: while the development of autonomous systems races ahead, practice lags behind. The leap from pilot to a system that genuinely works remains a big challenge.

At the same time, internal and external clients expect more. Reliability, safety, and security are decisive buying criteria, and that comes with tighter timelines and growing competition.

Zühlke brings a large, interdisciplinary team to Physical AI projects, from cybersecurity through data architectures, hardware development, artificial intelligence, and software engineering to transformation consulting. Together we industrialise and integrate autonomous systems, and we make sure they run safely and create measurable value.

Our focus is the intelligence in the product, not the optimisation of internal processes. We mean AI that sits right inside the device (AI on the edge): in the robot, in the drone, in the machine, perceiving, deciding, and acting there. That's exactly where our competencies come in.

Talk to us

What you get with Zühlke

Whether you develop autonomous systems yourself or want to deploy them in your value chain: with Zühlke you reduce your risks and reach your goals faster.

"" A booster for your product development

Our hardware engineering experts support you on the way from idea through prototypes to a market-ready series product, safely and with every certification you need. That way you speed up your time to market and reduce your risks.

More on our hardware engineering

"" Smarter systems thanks to intelligent data solutions

Does your product perceive, decide, and act in real time? Zühlke supports you in making your products genuinely intelligent and safe at the same time, with expertise in computer vision, sensor fusion, MLOps, and safety by design.

More on our data solutions

"" The right starting point for your autonomous systems project

Every beginning is hard, and that goes for autonomous systems too. We support you with well-founded use case and business case analyses, and we find the right solution for your application, vendor-neutral and with no interest in selling you hardware.

More on our digital strategy consulting

"" Autonomous systems that create measurable value

Autonomous systems create value when they're smoothly integrated into the systems and processes of your value chain. That's exactly what we make sure of for you, including IT/OT integration, fleet orchestration across manufacturers, and rules for human oversight, right through to approvable continuous operation.

More on our projects for industry

Let's take your next step together

Developing and integrating autonomous systems successfully is a big challenge. We're by your side to meet it.

Kontaktieren Sie uns

Talk to our experts

  • Jeannette Liniger

    Account & Initiative LeadcontentTeam.linkedinProfileOf Jeannette Liniger
  • Mario Schmuziger

    General Manager Industry & Consumer Goods & Partner, SwitzerlandcontentTeam.linkedinProfileOf Mario Schmuziger
  • Nikolaos Tachatos

    Nikolaos Tachatos

    Senior Consulting ManagercontentTeam.linkedinProfileOf Nikolaos Tachatos
  • Peter Guentzer

    Peter Güntzer

    Director Data & AI Consulting, PartnercontentTeam.linkedinProfileOf Peter Güntzer

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