In today’s fast-evolving industrial landscape, the integration of advanced robotics into manufacturing and process operations has transformed productivity and precision. However, with this evolution comes a new frontier of risk: cybersecurity. As collaborative robots, or cobots, become more prevalent and work increasingly closer to humans, ensuring both their functional safety and cybersecurity is no longer optional—it is essential.
For many years, the need for physical safety in robotic systems has been well understood. Traditional concerns have focused on mechanical hazards, physical proximity, and operational procedures to prevent injuries. However, as industrial robots become smarter, more interconnected, and internet-enabled, the attack surface for potential cyber threats expands significantly. This shift introduces a dual risk: not only can cyberattacks cause production downtime or data breaches, but they can also compromise the physical safety of operators and other equipment.
Understanding the risks
Industrial robots, like any complex electromechanical system, are susceptible to various cybersecurity threats. These include unpatched operating systems, unsecured internet protocols, default manufacturer passwords, and exposed physical interfaces such as USB or RJ-45 ports. In many cases, robots are left accessible for engineering or maintenance purposes, which may result in easy exploitation if basic cyber hygiene is not followed.
Traveling technicians often use laptops for diagnostics and updates—devices that, if not securely configured, may serve as a conduit for malware. Additionally, robots increasingly interact with external systems, from factory control networks and smartphones to cloud platforms managed by vendors. These connections, while designed for operational efficiency and remote support, can inadvertently introduce significant vulnerabilities.
Data and access control challenges
Data confidentiality has historically been overlooked in robotic system design. Communications may be left unencrypted or poorly protected, making them susceptible to interception or manipulation. Identity and access management (IAM) is another critical area. Improper IAM implementation can allow unauthorized users to make changes that could affect manufacturing quality or safety.
Common bad practices—like using shared credentials, displaying passwords on sticky notes, or failing to enforce basic user authentication—can open the door to serious incidents. Even worse, some systems may entirely forgo credential requirements, relying on convenience at the cost of security.
Unique considerations for different robot applications
While industrial robots typically don’t handle personal data, medical or service robots used in healthcare environments certainly do. These devices process sensitive health information and, as such, must comply with local and international data protection regulations. Manufacturers that fail to implement adequate cybersecurity controls risk being excluded from healthcare networks or violating patient privacy laws.
When robots are decommissioned, another risk emerges: residual data. Sensitive information stored in non-volatile memory or leftover G-code could be exploited by competitors or cybercriminals if not properly erased or destroyed.
Cybersecurity is now a core element of functional safety
The lines between functional safety and cybersecurity are increasingly blurred. A robot may be fully compliant with safety standards, but if its systems can be tampered with via cyberattack, it can no longer be considered truly safe. Functional safety alone is no longer sufficient; a holistic approach that integrates cybersecurity at every level is necessary.
Cyber threats evolve constantly. These include both technical vulnerabilities (like software bugs) and human-driven threats (such as phishing or insider sabotage). As hackers show growing interest in robotic systems, businesses must take proactive steps to understand and mitigate these risks.
A structured approach to cybersecurity: the NIST framework
One of the most effective methodologies for managing cyber risks is the NIST Cybersecurity Framework (CSF), built around five core functions: Identify, Protect, Detect, Respond, and Recover. Originally developed for critical infrastructure, this framework is equally applicable to industrial robotics, enabling organizations to understand and strengthen their overall security posture.
Organizations can enhance transparency and accountability by creating a Risk Traceability Matrix. This document outlines identified threats and the corresponding controls implemented to mitigate them. Such tools enable manufacturers, integrators, and operators to align on responsibilities and maintain layered defenses.
Best practices for manufacturers, integrators, and operators
Each stakeholder in the robotics ecosystem plays a vital role in cybersecurity.
Manufacturers should:
- Review robot security design
- Conduct hazard and threat modeling
- Provide secure code reviews
- Implement vulnerability and penetration testing
- Review component and architecture vulnerabilities
- Establish a patch management and update protocol
Systems integrators, who face unique challenges when deploying multiple robots in interconnected environments, should:
- Analyze system-wide design intersections
- Conduct code reviews and dynamic testing
- Coordinate with manufacturers on threat mitigation
- Recommend and implement additional security controls
Operators, responsible for day-to-day use, must:
- Perform plant-wide cybersecurity assessments
- Maintain software updates and patches
- Develop and routinely test incident response plans
- Ensure proper access controls are enforced
Relevant standards: IEC 61508 and IEC 62443
The IEC 61508 standard for functional safety explicitly states that when security threats are foreseeable, a corresponding analysis must be carried out. It recommends following the IEC 62443 series, which provides comprehensive guidelines for securing industrial control systems—including robots.
These standards stress the importance of integrating cybersecurity from the very beginning of system design. Combining IEC 62443 testing with traditional vulnerability assessments gives organizations a solid foundation to build safe and secure robotic systems.
Security as a catalyst for sustainable innovation
Industrial robots offer tremendous benefits in terms of productivity, precision, and innovation. Yet these gains are at risk if cybersecurity is not treated with the same rigor as functional safety. The reality is clear: a robot cannot be deemed safe if it is not secure.
By adopting a cyber risk-driven approach—supported by international standards, structured frameworks, and thorough testing—manufacturers, integrators, and operators can navigate the complexities of industrial robotics with confidence. In doing so, they not only protect their assets and personnel but also position themselves for sustainable, secure growth in an increasingly digital and automated world.
Discover more in TÜV Rheinland’s landing page and download the whitepaper “Industrial Robotics and Cybersecurity” here.
For the past decade, John McDonald has served as Principal Consultant and Practice Manager at TÜV Rheinland of North America, where he has focused on helping organizations address complex risk-related challenges and safeguard critical assets. He is a seasoned Cyber Security expert with
more than 40 years of experience in IT security, spanning multiple industries, regulatory frameworks, and security standards, and covering virtually every discipline in the field. His career path has included roles ranging from consultant and project manager to executive-level positions, including CxO responsibilities. He has authored numerous whitepapers, reports, and presentations, delivered more than 500 executive-level cybersecurity briefings to Fortune 1000 companies worldwide, and spoken at corporate and industry events across the globe, building a reputation as a trusted advisor and thought leader in the field.
