1. Why do humanoid robots need to achieve lightweight design?Lightweight Design: The Key to Cost Reduction and Efficiency in RoboticsLightweight design in new energy vehicles can significantly enhance range: According to the prospectus of Xingyuan Zhuomai, the weight of a vehicle greatly affects the range of new energy vehicles. With the same battery capacity, reducing the weight of a car by 10% can improve its range by 7%. The significance of lightweight design in humanoid robots: 1) Range: Similar to new energy vehicles, reducing the weight of robots can also enhance their range. The Tian Gong Ultra, which participated in the “First Robot Half Marathon Challenge,” used carbon fiber materials to reduce weight, significantly improving its range and winning the competition. 2) Response Speed: By implementing lightweight design, the weight of various joints and the torso of the robot can be reduced, lowering the moment of inertia during operation. The lower the moment of inertia, the less torque the motors of the humanoid robot require for acceleration and deceleration, resulting in higher dynamic response speed during movement.Lightweight design in robotics is an inevitable trendAs humanoid robots continue to advance towards general artificial intelligence platforms and real-world applications, the overall structural weight has become a key factor limiting mobility, energy efficiency, range, and adaptability to different scenarios. Currently, mainstream manufacturers generally consider “lightweight design” as one of the core aspects of iteration, continuously reducing the overall mass through self-developed high-torque density motors, topological optimization structures, integrated servo modules, carbon fiber, and composite materials.Mainstream technical routes: Currently, lightweight design in robotics mainly utilizes materials such as aluminum alloys, magnesium alloys (or aluminum-magnesium alloys), carbon fiber, and high-performance engineering plastics like PEEK. Aluminum alloys are widely used in structural components due to their cost-effectiveness; magnesium alloys are lighter and have good damping properties, making them suitable for weight reduction in load-bearing parts; carbon fiber has high strength and rigidity, commonly used in limbs and shells where weight is critical; PEEK, with its high strength and wear resistance, excels in joints, insulation, and complex structural components. Trend prediction: Multi-material synergy. Single materials struggle to balance strength, rigidity, cost, and processing technology. The future trend is the collaborative application of multiple materials such as magnesium alloys, carbon fiber, and PEEK, optimizing design based on functional zoning.2. Magnesium Alloys: Cost Reduction & Maturing Die-Casting Technology, Expected Increase in Penetration RateMagnesium Alloys vs. Aluminum Alloys — Magnesium Alloys Offer Better Cost-Performance RatioAs a lightweight material, magnesium alloys have significant performance advantages: the density of magnesium alloys is only 2/3 that of aluminum alloys, yet they exhibit comprehensive advantages in specific strength, shock absorption, electromagnetic shielding, and processing performance. They are particularly suitable for structural components that require high lightweight, energy absorption, and forming efficiency. In recent years, with the increasing demand for weight reduction and structural integration in new energy vehicles and robotics, magnesium alloys are gaining widespread attention as an ideal substitute for aluminum.High costs and processing challenges have historically constrained the development of magnesium alloysThe three historical bottlenecks of magnesium alloy applications: Despite their outstanding performance advantages, the high cost, complex forming processes, and corrosion resistance issues of magnesium alloys have historically limited their industrialization. Improvements in both price and processing technology are driving the increased penetration of magnesium alloys. In terms of price: Before 2021, the magnesium-aluminum price ratio was consistently above 1.5, limiting the penetration of magnesium materials; in recent years, as magnesium prices have weakened, the magnesium-aluminum ratio has dropped to nearly 1.0, gradually alleviating price pressures. In terms of processing: Semi-solid magnesium alloy die-casting technology has improved the safety of magnesium alloy processing, while composite coating technology has enhanced the corrosion and oxidation resistance of magnesium alloys, continuously improving their performance.Semi-solid die-casting technology addresses the processing challenges of magnesium alloysSemi-solid injection molding (Thixomolding) is an advanced processing method for magnesium alloys, where metal particles are heated and sheared to a semi-solid state before being injected into molds for forming. Compared to traditional high-pressure die-casting, it offers higher safety and forming stability. Brief process steps: 1) Feeding: Magnesium alloy particles (Mg chips) enter the screw machine barrel from the hopper. 2) Heating and shearing: The screw rotates in conjunction with multi-stage heating (580–630°C) to form a semi-solid slurry containing spherical solid phases. 3) Material compaction: The slurry is compacted in the front section of the barrel to increase density and fluidity. 4) Injection molding: The slurry is injected at high speed through the nozzle into the mold, rapidly cooling and solidifying in a closed mold to obtain dense, precise parts. Process highlights: safety, stable quality, and wide applicability.Application side: Magnesium alloy applications in the automotive sector are still in the early stages, with vast potential for growthBoth application volume and efficiency are increasing, accelerating industry penetration. The automotive sector accounts for 70% of magnesium alloy consumption, covering 10 major systems and over 100 components; the per vehicle usage in China is expected to increase from 6 kg in 2022 to 12 kg by 2024, while in North America, it is projected to reach 18 kg; according to the “Energy Saving and New Energy Vehicle Technology Roadmap 2.0,” the targets for 2025 and 2030 are 25 kg and 45 kg, respectively, with a CAGR of 17.9%.Technological and scenario breakthroughs drive the volume of structural components. 1) Leading companies such as SAIC, Baowu, and Xingyuan Zhuomai have achieved breakthroughs in structural components like electric drive housings, battery packs, and subframes: SAIC’s second-generation magnesium alloy electric drive housing, produced using semi-solid casting technology, has improved mechanical performance by 20%, with the qualification rate rising from 78% to 95%, and costs reduced by 18%; Baowu Magnesium has established the world’s first 6000T magnesium alloy die-casting unit, achieving integrated body structural components with a 30% weight reduction compared to traditional steel-aluminum structures. 2) The eVTOL aircraft’s main load-bearing structure (40% weight reduction) is rapidly penetrating emerging fields; EHang’s intelligent drone has effectively increased payload by 15% after adopting a magnesium alloy frame.Xusheng Group: Has established cooperation with multiple humanoid robot clientsRevenue slightly declined, and profits are under pressure. From 2020 to 2024, the company’s revenue grew from 1.628 billion yuan to 4.409 billion yuan, with a CAGR of 28%; net profit attributable to the parent company increased from 333 million yuan to 416 million yuan, with a CAGR of 6%. During this period, the company’s gross margin decreased from 32.86% to 20.28%, and the net profit margin dropped from 20.45% to 9.44%, with the decline in profitability mainly due to rising production costs. The company is advancing the application of magnesium alloy lightweight design and expanding into the robotics market. It has prioritized intelligent magnesium structural components and is actively developing key parts such as joint housings and torso structures, securing projects from multiple domestic and international clients.3. PEEK Materials: Excellent Comprehensive Performance, Expected to be Applied in Core Joint ComponentsThe Pearl of Special Engineering Plastics, Combining Highest Performance and Commercial ValueWith a long development history, PEEK is currently in a phase of monopoly dissolution and emergence of multiple strong players. PEEK, or polyether ether ketone, is a type of special engineering plastic that has developed over nearly 50 years. It was first developed by Imperial Chemical Industries (ICI) in the UK and applied in the military sector, with a production capacity of only 400 tons/year. In 1993, ICI was acquired by Victrex, and under its monopoly, PEEK gradually expanded into the civilian high-tech field, with production capacity rapidly increasing to 2800 tons/year by 2003. In 2005, Evonik and Jilin University established a joint venture, successfully producing commercialized PEEK after five years of research and development, marking the beginning of an era with multiple strong players.Industrial varieties are scarce, combining the highest performance and commercial value. According to the prospectus of Zhongyan Co., while there are dozens of PEEK varieties published in papers, fewer than ten have achieved commercialization. The extremely high technical barriers also endow PEEK materials with the highest performance and commercial value among engineering plastics.
Performance: Excellent Physical and Processing CharacteristicsPEEK possesses a variety of excellent physical and processing characteristics. According to the prospectus of Zhongyan Co., in terms of physical properties, PEEK exhibits good mechanical properties, flame resistance, wear resistance, corrosion resistance, hydrolysis resistance, heat resistance, peel resistance, and biocompatibility. Additionally, PEEK has excellent processing characteristics, making it easy to mold by injection, extrusion, and machining.Performance: Replacing Steel with Plastic, Becoming a Lightweight SolutionPEEK replaces steel with plastic, becoming a lightweight solution. According to the prospectus of Zhongyan Co., PEEK’s performance is comprehensively superior to that of ordinary metals. PEEK has a high specific strength, allowing for significant weight reduction while meeting strength requirements, making it a solution for achieving “lightweight”. Furthermore, PEEK outperforms ordinary metals in terms of insulation and chemical resistance. Compared to zirconium and titanium alloys, PEEK is more suitable as a material for medical implants, as its density and elasticity closely match human bone levels, and it is less thermally conductive, enhancing comfort after implantation. Additionally, as a non-metallic material, PEEK can be penetrated by X-rays and allows for CT scans, facilitating medical examinations for patients.Industry Chain: Core Raw Material Fluoroketone Production Concentrated in China, Market Structure is ConcentratedFluoroketone is the core raw material for PEEK, accounting for about 50% of the cost. According to the prospectus of Zhongyan Co., producing 1 ton of PEEK requires approximately 0.7-0.8 tons of fluoroketone monomer, with the cost of fluoroketone raw materials accounting for 50% of PEEK’s cost, making it the most critical raw material. The production capacity of fluoroketone is mainly concentrated in China, with few industry players leading to a concentrated competitive landscape. Globally, fluoroketone production is dominated by China, with overseas manufacturers primarily including Victrex from the UK, Solvay from Belgium, and Evonik from Germany (with Victrex being the main player). In China, major producers include Xinhang New Materials, Zhongxin Fluorine Materials, and Yingkou Xingfu. The fluoroketone market is relatively small, with few participants, leading to a concentrated market structure, and currently, Chinese fluoroketone producers dominate the global market. The consumption of fluoroketone in China has been steadily increasing. From 2019 to 2023, the consumption of fluoroketone in China grew from 479 tons to 2550 tons, showing steady growth. In terms of price, the price of fluoroketone is approximately 350 yuan per kilogram.Supply Side: One Dominant Player and Many Strong Competitors, Domestic Substitution Driving Down PEEK PricesThe current supply side presents a situation of one dominant player and many strong competitors, with the overall market controlled by overseas companies. According to the annual report of Zhongyan Co. and our grassroots research, Victrex from the UK holds an absolute advantage, with domestic production capacity of 7150 tons, accounting for about 60% of the global market, while its joint ventures in Panjin and Liaoning Xingfu also have a capacity of 800 tons. Following Victrex are Solvay from Belgium and Evonik from Germany, with production capacities of 2500 and 1800 tons, respectively. Domestically, Zhongyan Co. and Pengfulong each have a capacity of 1000 tons, while Jilin Juke and Shandong Junhao have capacities of 800 and 300 tons, respectively.Domestic substitution has already shown results, significantly driving down PEEK prices. According to our grassroots research, domestic substitution has significantly pushed down PEEK prices since 2017, with prices for PEEK from Victrex, Zhongyan Co., and Solvay Industrial decreasing from 1000, 500, and 650 yuan per kilogram to 600, 300, and 400 yuan per kilogram, respectively. It is expected that as domestic manufacturers release capacity, PEEK prices will have further room for decline.Application Side: Expected Market Size of PEEK Materials for Robotics to Reach 35 Billion Yuan by 2035With the increase in robot sales, the market size for PEEK materials in robotics is expected to reach 35 billion yuan by 2035. According to our predictions, the demand for humanoid robots is expected to grow from 25,000 units in 2025 to 11.65 million units by 2035. As PEEK manufacturers release capacity, the price of PEEK materials may decrease from 340 yuan/kg to 200 yuan/kg, further driving up the penetration rate of PEEK, with the per-unit usage expected to increase from 2 kg to 15 kg. Considering these factors, we estimate that by 2035, the market size for PEEK materials in robotics could reach 35 billion yuan. (Source: National New Materials Industry Resource Sharing, copyright belongs to the original author, please contact us for deletion in case of infringement)