Global shipments of physical AI devices are set to surge, with a total of 145 million units expected to ship worldwide between 2025 and 20235, according to new study from Counterpoint Research.
The figures come from Counterpoint’s Global Physical AI Market Tracker Report, which examines the rapid expansion of AI-enabled hardware across multiple industries. The report highlights how physical AI is moving from experimentation into real-world deployment at scale.
While much of the AI conversation today centres on software, algorithms and large language models (LLMs), physical AI focuses on machines that can perceive, decide and act in the real world. These systems combine artificial intelligence with sensors, hardware and connectivity to interact autonomously with their surroundings.
Counterpoint’s analysis concentrates on four core segments driving the market: vehicles, robots, drones and AI cameras. Other emerging applications - such as AI‑powered medical devices and industrial Internet of Things (IoT) sensors - were not included in the study.
According to Counterpoint principal analyst Soumen Mandal, physical AI represents the next major phase of AI adoption: “While the first AI wave focused on digital intelligence - software that understands text, images and data - the next wave brings AI into the physical world, allowing machines to perceive their surroundings and interact autonomously.”
AI robot shipments set for rapid growth
Within the robotics segment, AI‑enabled service robot shipments are expected to rise sharply as adoption accelerates across logistics, warehousing, hospitality, healthcare, cleaning, security and agriculture.
Humanoid robots are forecast to be the fastest‑growing category. Counterpoint predicts cumulative shipments will reach 100,000 units by 2028, representing a seven‑fold increase in just three years compared with 2025 levels.
Growth in AI‑capable self‑driving vehicles is expected to be more gradual. Vehicles with Level 4 (L4) autonomy - capable of operating without human intervention - continue to face regulatory and safety hurdles. However, uptake is forecast to increase as autonomous taxi services and consumer self‑driving models expand in more regions.
Commercial AI drones benefit from lower barriers
Commercial drones with AI capabilities are also set to see strong cumulative growth. This is driven by their comparatively lower average selling prices, alongside clearer regulatory frameworks emerging in major global markets. Use cases span inspection, monitoring, mapping and logistics, supporting wider enterprise adoption.
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