Benchmark H3.1
The Hardest Part of Making Physical AI Work
Survey question
Thinking about getting physical AI to work reliably in the real world, which of the following is the hardest part today?
- Audience
- All qualified buyers, n=85
- In depth
- Hypothesis 3 — A Systems Market, Not a Model Market Hypothesis 4 — Evaluation Discipline as the Signal
Buyers ranked their top three, so the shares add to more than 100%.
69%
of robotics buyers rate integrating the robot into their existing workflow among the three hardest parts of making physical AI work. It is the highest of any option, and the most-named first choice at 32%.
All qualified buyers, n=85
| Category | In top three (%) | Hardest of all (%) |
|---|---|---|
| Integrating it into the real workflow / environment | 69% | 32% |
| Operating it live — monitoring, diagnosing failures, updating safely | 55% | 20% |
| Getting enough good data and being able to simulate / test | 45% | 9% |
| Knowing how to measure whether it's actually working (evaluation) | 34% | 5% |
| Safety and security | 32% | 13% |
| The underlying AI model / autonomy | 32% | 11% |
| The robot hardware itself / on-device compute | 21% | 6% |
| Still evaluating / not applicable | 12% | 5% |
All qualified buyers, n=85
Benchmark H3.2
What Stops Buyers Scaling
Survey question
What are the biggest barriers to deploying or scaling robots / physical AI?
- Audience
- All qualified buyers, n=85
- In depth
- Hypothesis 3 — A Systems Market, Not a Model Market
Buyers ranked their top three, so the shares add to more than 100%. A “no significant barriers” option was offered and taken by nobody.
51%
of robotics buyers name integrating with existing operations and systems among their three biggest barriers to deploying or scaling. It is the most-named barrier.
All qualified buyers, n=85
| Category | In top three (%) | Biggest barrier (%) |
|---|---|---|
| Integration with existing operations and systems | 51% | 16% |
| Upfront cost / capital required | 44% | 20% |
| Reliability / performance in real conditions | 39% | 11% |
| Security and data concerns | 28% | 8% |
| Difficulty changing existing workflows / processes | 24% | 8% |
| Unclear or unproven ROI | 22% | 7% |
| Workforce concerns and change management | 21% | 5% |
| Availability of high-quality training data | 20% | 8% |
| Supply chain or manufacturing capacity constraints | 19% | 5% |
| Safety and risk to people | 14% | 7% |
| Lack of internal expertise | 13% | 4% |
| Vendor dependence / lock-in | 6% | 1% |
All qualified buyers, n=85
Benchmark H3.3
Where Deployment Cost Goes
Survey question
Roughly how is the cost of a physical AI deployment split across the following?
- Audience
- Qualified buyers who allocated, n=77 — the other 8 answered “still evaluating” and are excluded rather than counted as zero
- In depth
- Hypothesis 3 — A Systems Market, Not a Model Market
Buyers split 100 points across three categories, enforced to sum to 100.
70%
of deployment cost goes to the robot and the AI model per robotics buyers’ own estimates, leaving 30% for the integration, evaluation, operations, safety and support work that surrounds them
Qualified buyers who allocated, n=77 · Spread across buyers: robot hardware 10–80%, AI model & autonomy 0–70%, everything around them 5–80%
| Category | Mean | Median |
|---|---|---|
| Robot hardware | 41% | 40% |
| The AI model & autonomy | 28% | 25% |
| Everything around them (data, evaluation, operations, integration, safety, support) | 30% | 30% |
Qualified buyers who allocated, n=77 · Spread across buyers: robot hardware 10–80%, AI model & autonomy 0–70%, everything around them 5–80%
Benchmark H3.4
Where the Surrounding Spend Goes
Survey question
Within that “everything around them” spend, where does the largest share go?
- Audience
- Qualified buyers who put at least 30 of their 100 points on the surrounding category, n=43
- In depth
- Hypothesis 3 — A Systems Market, Not a Model Market
Single-select, so the shares add to 100%.
70%
of the robotics buyers who spend meaningfully on the work around the robot put the largest share of that spend into live operations (monitoring, fleet management, incident response, updates) or workflow integration
Qualified buyers who put at least 30 of their 100 points on the surrounding category, n=43
| Category | % |
|---|---|
| Live operations (monitoring, fleet management, incident response, updates) | 37% |
| Workflow / environment integration and customization | 33% |
| Data collection, simulation and evaluation | 16% |
| Safety, security and compliance | 9% |
| Field support and human supervision / teleoperation | 5% |
Qualified buyers who put at least 30 of their 100 points on the surrounding category, n=43
Benchmark H3.5
How Buyers Obtain the Capability
Survey question
How are the robots / physical AI capabilities obtained in the deployments you are closest to?
- Audience
- All qualified buyers, n=85
- In depth
- Hypothesis 3 — A Systems Market, Not a Model Market
Select all that apply, so the shares add to more than 100%. Buyers named 1.9 routes each on average.
Directional
71%
of robotics buyers take a complete solution from a robotics vendor — but buyers already running at scale add their own assembly on top, with 56% also using a systems integrator and 53% buying hardware separately
Packaged solutions lead across every stage, most often by buyers still piloting: 79%, compared to 69% at scale. What changes is what buyers add around these packaged solutions. 53% of scaled buyers also buy hardware separately and 56% use a systems integrator, as compared to 21% and 25% of those still piloting.
Segment bases are small (sizes shown in each column header); read differences across segments as directional, not precise
| Category | Scaled (n=32) | Limited production (n=29) | Piloting (n=24) |
|---|---|---|---|
| Complete solution from a robotics vendor (hardware + software) | 69% | 66% | 79% |
| Hardware bought and integrated / configured separately | 53% | 59% | 21% |
| Through a systems integrator | 56% | 38% | 25% |
| Built in-house | 25% | 3% | 25% |
| Rented / robots-as-a-service | 19% | 17% | 8% |
| Other | 0% | 0% | 4% |
Segment bases are small (sizes shown in each column header); read differences across segments as directional, not precise