Testing robotics in live airport cargo operations
The deployment of autonomous robots in airport cargo operations has shifted from research labs to real-world implementation. In Germany, what started as a research initiative has now advanced into active trials, with five autonomous robots tested directly within live operations at major airports, including Munich and Stuttgart.
Unlike controlled environments or warehouse simulations, these trials place robots directly into the bustling ecosystem of air cargo handling. They navigate alongside people, tractors, tugs, and loading vehicles, all while dealing with the unpredictability of airside logistics. According to Manuel Wehner, Project Lead at the Fraunhofer Institute for Material Flow and Logistics (IML) in Frankfurt am Main, the ambition is not just to design machines that can survive in such environments, but to create systems that enhance efficiency and resilience.
“We tested five robots so far along the actual process flow at the airport,” Wehner explained. “They were not positioned behind fences or in isolated zones, but placed in live operations—transporting containers and loading ULDs at our partner airports in Munich and Stuttgart.”
Autonomy in Dynamic Environments
While warehouse robots often rely on predefined paths or static environments, airport cargo robots face a constantly shifting operational landscape. Trucks may suddenly block a path, ground handling vehicles may change position, and human workers move unpredictably. Robots must therefore be fully autonomous, making decisions on the spot rather than relying on rigid pre-programming.
“The robot needs to be truly autonomous,” Wehner emphasized. “If someone parks in its path or a tractor suddenly drives by, it has to reroute or adapt instantly. A robot that simply freezes is not useful in these conditions.”
These trials are part of the Digital Testbed Air Cargo (DTAC) project, funded by the German Federal Ministry for Digitalization and Government Modernization (BMDS) with a budget of €13.7 million. The initiative is exploring multiple applications, including container transport, ULD loading and unloading, and integration with terminal gates. A new robot, designed specifically for ULD handling, is currently under development in IML’s laboratories, incorporating lessons from earlier testing phases. In parallel, the project is working on AI-driven algorithms for predictive cargo operations and applications aligned with IATA’s ONE Record data standard.
Robots as Part of Airport Infrastructure
A critical lesson from these trials is that successful automation goes beyond simply introducing advanced machines. It requires building an ecosystem in which robotics and digital infrastructure work together. For this reason, IML has been developing modular control systems that allow robots from different manufacturers to operate in parallel, ensuring scalability and avoiding dependency on a single vendor.
“The smarter the control software, the less complex the robot itself needs to be,” Wehner said. “This approach reduces cost, improves maintainability, and accelerates deployment.”
At the core of this vision is openTCS, IML’s open-source robot fleet management software. With over a decade of development history in other industries, openTCS enables plug-and-play integration of heterogeneous robotic vehicles. It is now being adapted for airport applications, ensuring that airports can integrate or replace robots without having to start from scratch.
“You don’t need to redesign the entire system if you switch manufacturers or robot types,” Wehner explained. “You simply adapt the control software and continue operations seamlessly.”
Learning from Real-World Deployment
One of the most valuable insights from live testing is that real airports present challenges that cannot be fully simulated. Misaligned pallets, poor lighting, unclear signage, and unexpected vehicle traffic have all exposed gaps in robot performance. These issues, while inconvenient, are essential for improving system design.
“It’s a good thing when it fails,” said Wehner. “That’s how we learn what needs improvement. Testing only in a lab won’t reveal these critical weaknesses.”
To minimize disruption during future deployments, the DTAC project is also developing digital twins and simulation tools. These will allow airports to rehearse full operations virtually before rolling out physical robots.
Building Open and Scalable Systems
The long-term goal of IML and the DTAC consortium is to support airports in creating robotics ecosystems that are open, adaptable, and sustainable. Unlike commercial vendors seeking to lock in clients with proprietary systems, IML’s nonprofit approach emphasizes openness and flexibility.
“We are not a robotics company trying to sell hardware,” Wehner clarified. “As a nonprofit, our mission is to create public knowledge and tools that airports can adapt to their own needs.”
This approach is particularly relevant for smaller and regional airports. These facilities often face the same workforce shortages as larger hubs but lack the budget for large-scale automation projects. By offering modular, low-cost systems driven by smart software, IML aims to make robotic solutions accessible beyond the major international gateways.
Collaboration and Digital Standards
Looking ahead, Wehner believes that the success of robotics in air cargo will depend heavily on cooperation between stakeholders. From data interfaces and fleet management APIs to regulatory frameworks, digital standards will be critical in ensuring interoperability and scalability.
“Everyone talks about digitalisation,” Wehner noted, “but unless you know what data you actually need and how to use it, it has little value. The real question is: what do you do with the data?”
Recognition and Next Steps
The DTAC consortium’s efforts have already gained international recognition. In 2024, its heterogeneous robot fleet trials at Munich and Stuttgart earned awards, including TIACA’s Sustainability Award in Hong Kong (June 2025) and the International Award for Excellence in Air Cargo in Nairobi (February 2025). The project was also a top-five finalist at the ACW World Air Cargo Awards in Munich in June 2025.
These milestones highlight the growing acceptance of robotics in live airport environments and underscore the potential of collaborative, open-source approaches to solving industry-wide challenges.
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