Brooke Robison Mar 24 With physical AI, Mech superhumanoid robots excel in unpredictable warehouse environments with EtherCAT and PC-based control from Beckhoff. The Mech superhumanoid robot features two arms with a unique sense of touch, infusing human-like dexterity through Physical AI. From patchwork to powerhouse tech At the beginning of 2025, Dexterity kicked their engineering work with Beckhoff into high gear, collaborating with Beckhoff USA’s Special Project Team (SPT) to complete the software development required for this application. This approach allowed Dexterity to streamline everything from initial commissioning to fleet-wide software updates and remote debugging. Instead of having to manage disparate systems that struggled to communicate, Beckhoff’s universal and open control architecture created a consistent foundation for interoperability and the required modularity to scale. Dexterity’s engineering team also attended Beckhoff training courses, shortening the learning curve and speeding up commissioning. While EtherCAT heavily factors into the design, the breadth of Beckhoff’s communication portfolio to incorporate other networks also played an important role in bringing Mech to life. Dexterity uses CAN bus alongside EtherCAT, overcoming the typical barriers between legacy and next-generation systems. Together, the combination of PC-based control, EtherCAT networking, TwinSAFE functional safety, and modular I/O provided Dexterity with the performance, safety, and scalability needed to bring physical AI-powered robots into production environments. Mech features a 5+ meter arm span and can handle payloads up to 60kg, allowing the system to manipulate millions of different types of parcels and packages. Under the hood: Embedded controller brains, one cable magic, and more This full stack approach was integral to reaching the performance, safety, and flexibility standards needed to bring physical AI-powered robots into real-world production environments and ensure that Mech performs at its best in the field for years to come. Better, faster, stronger warehousing Beyond individual warehouses, the real breakthrough comes at the network level. Because Mechs generate streams of high-quality data, such as throughput metrics and operational bottlenecks, organizations will be able to dynamically implement continuous improvement measures and shift capacity across distribution centers. For example, if one facility faces delays due to late shipments, additional capacity can be allocated to nearby sites, ensuring that the overall logistics network remains resilient and efficient. In short, Mech is poised to reshape logistics by unlocking new capabilities and elevating the entire supply chain ecosystem. Scalable robotics: Mech beyond the warehouse (From left): Shawn Lange, Beckhoff; Doug Schuchart, Beckhoff; Robert Sun, Dexterity; Gil Matzliach, Dexterity; David Turney, Dexterity; Michael Perry, Dexterity; Nathan Hibbs, Beckhoff; Peng Chen, Beckhoff. By combining their robotics expertise with Beckhoff’s integrated automation technology, Dexterity is redefining what’s possible in logistics: smarter, AI-driven operations, safer workplaces, and a future where humans and robots work side by side to keep supply chains moving at full speed. Brooke Robison is the Social Media Specialist at Beckhoff Automation LLC