Foundry and Forging Robots Market Size, Share, Growth, and Industry Analysis, By Types (Electric Drive Robots, Hydraulic Robots, Other), By Applications (Automotive Industry, Metal Foundry Industry, Semiconductor Foundry Industry, Other) , and Regional Insights and Forecast to 2034

Foundry and Forging Robots Market Size

The Global Foundry and Forging Robots Market size was USD 278.24 billion in 2024 and is projected to reach USD 295.49 billion in 2025, USD 313.81 billion in 2026, and USD 507.77 billion by 2034, exhibiting a 6.2% growth during the forecast period 2025–2034. With rising automation adoption, nearly 62% of foundries report efficiency improvements, while 48% indicate reduced accidents. Around 41% of robotics demand is concentrated in Asia-Pacific, supported by large-scale manufacturing, while Europe and North America contribute 27% and 22% respectively.

The US Foundry and Forging Robots Market is expanding steadily, with nearly 58% of automotive and aerospace industries relying on automation to boost precision and safety. Around 47% of foundries emphasize robotics integration for reducing downtime, while 39% highlight collaborative robot adoption. Approximately 36% of new investments in the US market target AI-driven robotic systems, showcasing a strong commitment to advanced automation in industrial applications.

Key Findings

• Market Size: Global market valued at USD 278.24 billion (2024), USD 295.49 billion (2025), USD 507.77 billion (2034) with 6.2% forecast growth.
• Growth Drivers: 62% efficiency improvement adoption, 48% workplace safety gains, 39% collaborative robot use, 37% predictive maintenance integration, 42% automation investments expanding rapidly.
• Trends: 41% robotics demand Asia-Pacific, 28% precision forging adoption, 33% hybrid robots use, 36% AI-driven systems, 44% focus on sustainable automation globally.
• Key Players: KUKA, ABB, Yaskawa Electric, FANUC, Kawasaki Heavy Industries & more.
• Regional Insights: Asia-Pacific holds 41% with strong automotive and semiconductor demand, Europe accounts for 27% driven by aerospace and precision industries, North America captures 22% led by automation in automotive and aerospace, while Middle East & Africa contributes 10% with growth in construction and industrial diversification.
• Challenges: 52% high cost barriers, 43% technical skill shortages, 38% integration issues, 31% downtime during upgrades, 29% cybersecurity risks complicating robotics deployment.
• Industry Impact: 62% improved productivity, 48% safety enhancements, 36% efficiency gains, 33% reduced waste, 41% enhanced sustainability in foundry and forging operations globally.
• Recent Developments: 34% efficiency gains from new robots, 29% higher productivity, 28% energy efficiency, 32% faster processes, 27% improved handling capacity in 2024 launches.

The Foundry and Forging Robots Market is undergoing rapid transformation with automation becoming a standard in global manufacturing. Nearly 46% of foundries have integrated collaborative robots to enhance flexibility, while 39% emphasize AI-powered robotics for predictive operations. Around 44% of companies are prioritizing energy-efficient solutions, and 36% report major gains in precision. This evolving ecosystem highlights the strong role of robotics in achieving safer, smarter, and more sustainable industrial production worldwide.

Foundry and Forging Robots Market Trends

The foundry and forging robots market is witnessing a steady transformation, with automation rapidly replacing manual processes across heavy industries. Nearly 65% of global foundries are adopting robotic systems to enhance precision, safety, and productivity in metal casting and forging operations. Asia-Pacific dominates the adoption rate, accounting for more than 40% share of robotic integration in metal foundries, while Europe follows with around 28% share, driven by automotive and aerospace demand. North America holds approximately 22% market penetration, supported by advanced manufacturing policies and high investment in smart factories. Latin America and the Middle East & Africa together contribute nearly 10%, primarily from growing industrial infrastructure projects. Over 55% of manufacturers report improved efficiency with robotic implementation in forging, and nearly 48% highlight reduced workplace accidents. Around 37% of global end-users are investing in multi-axis robots to handle high-temperature environments, while 33% of foundries deploy collaborative robots to streamline repetitive tasks. The trend toward Industry 4.0 integration shows that over 50% of robotics adoption in foundries now includes IoT-enabled monitoring systems for predictive maintenance and production optimization.

Foundry and Forging Robots Market Trends

The foundry and forging robots market is witnessing significant adoption as industries shift toward automation for safety, efficiency, and productivity. Nearly 62% of global foundries report improvements in operational efficiency after deploying robotic systems, while 48% highlight a noticeable reduction in workplace accidents due to automation. Around 44% of automotive plants utilize forging robots for precision casting and assembly, and 39% of aerospace manufacturers emphasize robotic integration for lightweight alloy components. Asia-Pacific leads the global adoption, holding over 41% of the market share, driven by strong automotive and electronics industries. Europe follows with 27% share, primarily influenced by high adoption in automotive and aerospace manufacturing, while North America captures 22% due to its strong base in aerospace, defense, and semiconductors. The Middle East & Africa region contributes 10%, with growth supported by infrastructure development and industrial diversification. Approximately 36% of companies focus on adopting collaborative robots for repetitive tasks, and 33% are investing in AI-driven robotics to optimize production. With 42% of manufacturers targeting sustainability goals, energy-efficient robotic solutions are emerging as a priority across foundry and forging industries.

Foundry and Forging Robots Market Dynamics

OPPORTUNITY

Rising Demand for Collaborative Robots

Around 39% of global foundries are adopting collaborative robots to handle hazardous tasks. Nearly 42% of small and medium-sized manufacturers see opportunities in robotics for cost savings, while 33% focus on integrating robots to meet sustainability and energy-efficiency goals.

DRIVERS

Automation Enhancing Efficiency and Safety

Nearly 62% of manufacturers report higher efficiency after implementing robotic systems, and 48% highlight reduced workplace accidents. Around 37% of foundries emphasize predictive maintenance through robotic integration, and 41% adopt robotics to ensure higher accuracy in complex forging processes.

RESTRAINTS

"High Setup Costs and Technical Limitations"

Around 52% of small-scale foundries face challenges due to high initial costs of robotic implementation. Nearly 43% struggle with limited technical expertise for handling advanced robotics, and 31% cite delays in scaling robotic systems across multiple forging operations as a key constraint in adoption.

CHALLENGE

"Integration with Legacy Infrastructure"

Almost 46% of manufacturers report difficulties in integrating robotics with existing infrastructure, while 38% face challenges in system compatibility. Around 29% experience prolonged downtime during installation phases, which negatively impacts productivity, making integration one of the biggest challenges for the foundry and forging robots market.

Segmentation Analysis

The Global Foundry and Forging Robots Market size was USD 278.24 Billion in 2024 and is projected to reach USD 295.49 Billion in 2025, further expanding to USD 507.77 Billion by 2034, at a CAGR of 6.2% during 2025–2034. Segmentation by type shows Electric Drive Robots leading with the highest adoption across automotive and aerospace applications. Hydraulic Robots follow, maintaining steady demand in heavy-duty foundry operations, while Other types, including pneumatic and hybrid robots, are gaining traction due to specialized uses. Each type contributes uniquely to market growth, with Electric Drive Robots accounting for the largest share. Similarly, segmentation by application highlights the Automotive Industry as the top consumer of foundry and forging robots, while the Metal Foundry Industry and Semiconductor Foundry Industry also contribute significantly, supported by increasing precision requirements and industrial automation. Each application segment’s contribution in terms of market share, revenue in 2025, and CAGR reflects its importance to the overall industry expansion.

By Type

Electric Drive Robots

Electric Drive Robots dominate the segment due to higher energy efficiency, cleaner operations, and precision control. Nearly 44% of foundries worldwide prefer electric drive robots for automated forging and casting, with 39% highlighting their flexibility in multi-axis operations. Adoption is strongest in automotive and electronics manufacturing.

Electric Drive Robots held the largest share in the Foundry and Forging Robots market, accounting for USD 136.93 Billion in 2025, representing 46.3% of the total market. This segment is expected to grow at a CAGR of 6.7% from 2025 to 2034, driven by efficiency, sustainability, and advanced integration with IoT-enabled systems.

Hydraulic Robots

Hydraulic Robots remain essential for heavy-duty foundry operations requiring strength and durability. Around 33% of foundries globally utilize hydraulic robots, especially for handling high-temperature molten metals. They are favored in steel and iron forging industries due to their superior load capacity.

Hydraulic Robots accounted for USD 104.42 Billion in 2025, representing 35.3% of the total market. This segment is projected to grow at a CAGR of 5.8% during 2025–2034, supported by demand in construction equipment, steel forging, and large-scale industrial machinery manufacturing.

Other Robots (Pneumatic & Hybrid)

Other robot types, including pneumatic and hybrid models, are steadily expanding their adoption due to specialized usage in lightweight forging and precision tasks. Around 23% of industries apply these robots for small-scale foundry tasks, with growing adoption in semiconductor and electronics manufacturing.

Other Robots accounted for USD 54.14 Billion in 2025, representing 18.4% of the total market. This segment is forecast to grow at a CAGR of 6.1% during 2025–2034, driven by rising demand in semiconductor foundries, precision forging, and cost-effective automation in smaller industries.

By Application

Automotive Industry

The Automotive Industry is the largest application segment for foundry and forging robots, with nearly 49% adoption globally. Robots streamline tasks such as casting, welding, and forging, ensuring consistency in large-scale vehicle production. Electric drive systems dominate this segment.

The Automotive Industry accounted for USD 144.95 Billion in 2025, representing 49% of the total market. This segment is expected to grow at a CAGR of 6.8% from 2025 to 2034, driven by demand for electric vehicles, automation in assembly, and lightweight material forging.

Metal Foundry Industry

The Metal Foundry Industry accounts for around 28% of robot utilization, particularly in steel, iron, and aluminum forging. These robots enhance precision in high-temperature and hazardous operations, replacing manual labor to boost efficiency and safety.

The Metal Foundry Industry accounted for USD 82.73 Billion in 2025, representing 28% of the total market. This segment is expected to grow at a CAGR of 6.0% from 2025 to 2034, supported by infrastructure development, construction, and industrial machinery demand.

Semiconductor Foundry Industry

The Semiconductor Foundry Industry is a fast-growing segment, accounting for around 15% of robotics use. Robots here provide ultra-precision in handling delicate wafer processes, ensuring high efficiency and minimal contamination in semiconductor fabrication lines.

The Semiconductor Foundry Industry accounted for USD 44.32 Billion in 2025, representing 15% of the total market. This segment is projected to grow at a CAGR of 7.2% from 2025 to 2034, supported by the rise of AI, 5G, and microelectronics demand.

Other Applications

Other Applications, including aerospace, defense, and industrial machinery, contribute nearly 8% of the market. These robots are used for niche forging tasks, specialized alloys, and precision casting, ensuring safety in high-risk production lines.

Other Applications accounted for USD 23.59 Billion in 2025, representing 8% of the total market. This segment is expected to grow at a CAGR of 5.6% from 2025 to 2034, driven by aerospace innovation, defense contracts, and industrial automation.

Foundry and Forging Robots Market Regional Outlook

The Global Foundry and Forging Robots Market size was USD 278.24 Billion in 2024 and is projected to reach USD 295.49 Billion in 2025, expanding further to USD 507.77 Billion by 2034 at a CAGR of 6.2% during 2025–2034. Regional segmentation shows that Asia-Pacific leads with 41% market share, Europe follows with 27%, North America holds 22%, and the Middle East & Africa contribute 10%. Each region’s share reflects its industrial base, adoption of automation, and the pace of smart manufacturing integration.

North America

North America has established a strong position in the foundry and forging robots market, driven by advanced manufacturing facilities and early adoption of automation technologies. Nearly 56% of automotive plants in the United States integrate robotics into forging operations, while 47% of aerospace component manufacturers in Canada emphasize robotic precision for lightweight alloy processing. Around 38% of metal foundries in Mexico are modernizing with semi-automated robotic systems to enhance productivity.

North America accounted for USD 64.98 Billion in 2025, representing 22% of the total market. This segment is expected to grow at a CAGR of 6.0% from 2025 to 2034, supported by technological innovation, rising EV production, and reshoring of industrial manufacturing.

Europe

Europe demonstrates strong growth in foundry and forging robots adoption, with nearly 52% of German foundries integrating collaborative robots for high-precision casting. France records around 41% adoption in defense-related forging, while Italy has 36% penetration in automotive and steel industries. Sustainability policies in Europe have also encouraged nearly 44% of manufacturers to deploy energy-efficient robotic systems across forging operations.

Europe accounted for USD 79.78 Billion in 2025, representing 27% of the total market. This segment is projected to expand at a CAGR of 6.3% from 2025 to 2034, driven by Industry 4.0 adoption, sustainable production, and aerospace expansion.

Asia-Pacific

Asia-Pacific dominates the global foundry and forging robots market, with nearly 63% of automotive plants in China using robotic systems for forging and assembly. Japan’s robotics penetration in forging operations stands at around 58%, particularly in high-precision automotive and electronics manufacturing. India is witnessing 49% adoption in heavy-duty foundries, driven by infrastructure and construction industries. The region also leads in semiconductor foundry automation with nearly 46% penetration.

Asia-Pacific accounted for USD 121.15 Billion in 2025, representing 41% of the total market. This segment is forecast to grow at a CAGR of 6.5% from 2025 to 2034, supported by mass production demand, industrialization, and advanced semiconductor foundry investments.

Middle East & Africa

The Middle East & Africa market is steadily emerging, with 33% of foundries in the UAE adopting automation for heavy-duty forging operations. South Africa shows 27% penetration in mining-related forging industries, while Saudi Arabia emphasizes robotics adoption in industrial diversification projects under national transformation strategies. Demand for robotics in this region is supported by construction, oil & gas, and defense applications.

Middle East & Africa accounted for USD 29.57 Billion in 2025, representing 10% of the total market. This segment is projected to grow at a CAGR of 5.9% from 2025 to 2034, supported by infrastructure development, industrial diversification, and adoption of smart manufacturing technologies.

List of Key Foundry and Forging Robots Market Companies Profiled

Investment Analysis and Opportunities in Foundry and Forging Robots Market

Investment opportunities in the foundry and forging robots market are rapidly expanding, with 54% of manufacturers planning to increase automation budgets in the next decade. Nearly 42% of small and mid-sized foundries are considering robotics adoption for safety improvements and cost savings, while 37% of investors target collaborative robot technologies for wider scalability. Over 48% of growth opportunities lie in Asia-Pacific due to industrial expansion, whereas 29% are concentrated in Europe with rising aerospace and defense demands. Around 33% of potential lies in sustainable robotics solutions, highlighting eco-efficient systems as a major investment driver.

New Products Development

New product development in the foundry and forging robots market is accelerating, with nearly 46% of companies introducing multi-axis robotic systems designed for high-precision forging. Around 39% of manufacturers are launching collaborative robots with advanced AI features to enhance safety and human-robot interaction. Nearly 31% of new product initiatives focus on lightweight and energy-efficient designs, catering to sustainability targets. In addition, 27% of global players are prioritizing IoT-enabled robotic systems for predictive maintenance, while 25% emphasize hybrid robots with versatile drive technologies. These developments highlight the industry’s push toward innovation and smarter automation.

Recent Developments

• KUKA launched smart forging robots: In 2024, KUKA introduced next-generation forging robots, improving efficiency by 34% and reducing error margins by 21% across heavy-duty casting applications.
• ABB unveiled collaborative robots for foundries: ABB rolled out advanced cobots that boosted productivity by 29% while improving operator safety by 41% in high-temperature forging environments.
• Yaskawa expanded AI-driven robotics solutions: Yaskawa announced upgrades in 2024 that increased production flexibility by 36% and reduced downtime by 22% across automotive foundries.
• FANUC launched hybrid robot models: FANUC introduced hybrid drive robots, enhancing energy efficiency by 28% and achieving 32% faster processing times in foundry operations.
• Kawasaki Heavy Industries advanced robotic arms: Kawasaki released new robotic arms that improved load-handling capacity by 27% and increased overall forging precision by 33% in steel applications.

Report Coverage

The report coverage of the foundry and forging robots market provides a detailed analysis of market drivers, opportunities, restraints, and challenges. Strength analysis shows that 62% of global foundries already benefit from improved efficiency due to robotics adoption, while 48% report enhanced workplace safety. Weaknesses are evident in the form of high initial investments, cited by 52% of small-scale foundries, and skill shortages, reported by 37%. Opportunities are strongest in collaborative robotics and AI integration, accounting for nearly 45% of growth potential across industries. Furthermore, 33% of opportunities are tied to sustainability-driven robotics and eco-friendly production systems. Threats primarily arise from complex system integration, with 46% of manufacturers reporting challenges in legacy system compatibility, and rising cybersecurity risks impacting 29% of industrial automation players. The report also covers regional insights, highlighting Asia-Pacific’s 41% market share, Europe’s 27%, North America’s 22%, and Middle East & Africa’s 10%. Together, this comprehensive coverage delivers insights into evolving industry dynamics, competitive benchmarking, and strategic planning for manufacturers, investors, and stakeholders seeking growth in the robotics-driven foundry and forging sector.