As an industrial designer focused on the design and interaction of robots, I've spent the last 11 years designing various types of robots. By far, the most enjoyable and challenging projects have been humanoid robot designs. In this post, I’ll share some key tips for designers and roboticists navigating this exciting field.

A collection of most notable humanoid robots in 2025

Start with Questioning!

Before diving into the design process, there are several fundamental questions that need to be answered:

Who is this robot? What personality do you want to give it? What feeling or emotion should it evoke in the audience?
Who is this robot for? Who should fall in love with this robot at first sight?
How visible do we want this robot to be? Is it introverted or extroverted?
Where did this robot come from? Did it emerge from a cutting-edge lab, or was it created by an industrial enterprise showcasing its capabilities?
What capabilities of this robot do we want to expose? Which features should remain hidden?
What makes this robot stand out? What is the focus? Legs like Atlas, hands like Phoenix, or communication like Ameca?
What is the “one thing” you want people to remember about this robot? Make it memorable—one key feature, not two.
Which areas of this robot are human-like, and which are not? Consider which parts are directly inspired by humans and which are inspired by other artifacts.

These questions can also apply to individuals, helping you find deeper insights into your design. For instance, take a moment to reflect: Are you wearing glasses right now?

The answers to these questions will guide you through the design process, providing a foundation for the next critical steps. Designing a humanoid robot involves six main areas. A successful humanoid design strikes a balance across these factors, with each area contributing to the overall functionality and appeal of the robot.

1. Proportions

The most critical aspect of humanoid robot design is proportion. While designing proportions doesn't mean replicating the exact human body, it’s essential to achieve aesthetic and functional goals. Proportions help maintain balance and ensure that the robot performs as intended. For instance, designing the body based on factors like age, gender, and desired capabilities helps set the foundation for the proportions. A good practice is to use ratios, such as the golden ratio, for proportioning different body parts. This approach helps design efficient joints, like from the shoulder to the hand, using proportionate link sizes for better movement and aesthetic appeal.

2. Coverability

Coverability refers to how much of the robot’s system is covered by non-functional panels versus exposed components. It’s vital to strike the right balance, considering limitations like degrees of freedom (DoFs), weight, component sensitivity, and heat generation. There are three main approaches to coverability:

Full coverage: Common in robots designed for direct human interaction (e.g., Asimo, Pepper).
Partial cover: Provides flexibility and often used in robots like Tesla Optimus Gen 1.
Exposed structure: The inner structure is visible, contributing to a more industrial or utilitarian look (e.g., Atlas, industrial robots).

Choosing the right approach depends on the robot’s intended use and the image you want to convey.

3. Forms and Geometries

When designing the robot’s forms, consider whether the shapes should be based on human anatomy (bones, muscles, skin) or human artifacts (clothing, shoes). Consistency is key here, choosing one path and sticking to it creates a cohesive design. While some compromises may be necessary (since geometric shapes don’t exist exactly in nature), balancing organic and geometric elements leads to a more appealing design. Repeating geometric forms, like using a "squircle" shape for joints with one-degree-of-freedom, helps create a sense of unity throughout the robot’s design.

4. CMF (Color, Material, Finish)

CMF is crucial for establishing the robot’s aesthetic and personality. Color influences the robot’s perceived functionality, and materials contribute to its tactile feel. For example, a fabric-covered robot may seem friendly for elder care, while a metal-finished robot appears more industrial. The finish of materials adds the final touch, balancing gloss, matte, or texture to evoke the desired effect. The key here is repetition—choose a specific color or finish and apply it consistently across the design to unify the robot’s character. For further guidance, check out this blog for a comprehensive color guide.

5. Movement

The robot’s design should be evaluated not just in a static pose, but also in motion. As soon as the robot moves, the audience’s attention shifts to its movements. Therefore, the proportions, coverages, forms, and CMF must all be designed with the robot's movement in mind. Consider the robot’s degrees of freedom (DoFs) and center of gravity (CG), ensuring the design supports smooth and realistic motion. A good practice is to sketch the robot in various poses and movements, then simulate its movements to assess whether its appearance and character shift too much during motion.

6. Character

Designing a robot’s character is often the most challenging part. However, if you have a clear understanding of the robot’s personality, the task becomes easier. Pay attention to how the design elements, proportions, forms, and CMF, reflect the robot’s character. For example, an agile robot might have thinner legs, while a robot with a strong or sturdy character might have bulkier forms. Consider movements and animations that embody the desired personality. Remember, a robot’s character isn’t just about its face or expressions, its entire body, from head to toe, contributes to the overall character.

Designing a humanoid robot is an intricate process that requires collaboration across teams and a careful balance of aesthetic and functional considerations. The six areas mentioned above, proportions, coverability, forms, CMF, movement, and character, are essential to creating a robot that resonates with its audience and fulfills its intended role. Additionally, factors like lighting, sound, and voice design can further enhance the robot’s interaction with humans. By addressing these key elements thoughtfully, you can create a humanoid robot that is both functional and memorable.

Almost the last word

Designing a humanoid robot is an intricate process that requires collaboration across teams and a careful balance of aesthetic and functional considerations. The six areas mentioned above, proportions, coverability, forms, CMF, movement, and character, are essential to creating a robot that resonates with its audience and fulfills its intended role. Additionally, factors like lighting, sound, and voice design can further enhance the robot’s interaction with humans. By addressing these key elements thoughtfully, you can create a humanoid robot that is both functional and memorable.

Designing a Humanoid Robot: Considerations and Best Practices