Understanding ISO10218:2025 Robot Safety Standards

In 2025, new international safety standards for industrial robots and robot systems were released. But what do they really mean for manufacturers?

What is ISO 10218:2025?

ISO 10218:2025 is the new global benchmark used by robot manufacturers, system integrators and safety engineers to ensure robots can operate safely alongside people. It is a revised version of the previous 2011 edition.

Broken down, ISO 10218:2025 consists of two parts:

ISO 10218‑1:2025 – Industrial robots (Part 1)

· Defines safety requirements for robot manufacturers, covering inherently safe robot design, risk reduction measures and safety-related documentation.

ISO 10218‑2:2025 – Robot systems & integration (Part 2)

· Defines safety requirements for integrators and machine builders who incorporate robots into complete systems, production lines or collaborative workspaces.

Both parts apply to all sectors using industrial robots: automotive, electronics, medical, general manufacturing, and more.

A lot has changed since the previous ISO 10218 from 2011, and the new standards reflect that. Since 2011, collaborative robots have been widely deployed, with an increase in human-robot collaboration and AI-assisted technologies. The new standards also reflect the growing relevance of cybersecurity.

Here are the biggest updates that affect how collaborative robots (cobots) are used:

1. New Robot Categories

All types of robots now fall into new safety classes (such as Class I or Class II). These classes decide how much testing and safety proof you need. The updated ISO 10218:2025 removes the idea of collaborative robots being their own category. Instead, all robots (including UR cobots) are treated as industrial robots. Safety classification now depends on how the robot is used.

2. Cybersecurity Matters More Than Ever

Because today’s robots are often connected to networks, the updated rules now include cybersecurity. In simple terms: safety features must be protected from hacking or accidental interference. This ensures a cyber issue can’t turn off the robot’s safety systems.

3. Clearer Safety Guidance for Tools and Handling

The standards now spell out how to safely use the robot’s tools (the gripper or end‑effector) and how people should safely load or unload items by hand. This includes paying attention to risks like sharp tools, dropped parts or places where fingers could get caught.

4. Detailed Rules for Working Safely Near People

The rules around cobot‑specific features, like limiting how hard the robot can push (PFL) or slowing down when a person gets close (SSM), are now much clearer. They include exact limits and how to properly test them. Robots also have to undergo pressure tests to make sure forces stay within legal safe levels.

What this means for anyone using Universal Robots…

The updated Part 1 describes safety requirements for:

· Inherently safe design

· Protective measures

· Safety‑related information for use

UR cobots have long been designed around:

· Integrated force‑limiting

· Certified safety functions

· Built‑in risk‑reduction tools

· Extensive safety documentation

All of which directly map onto ISO 10218‑1’s scope.

As cobots continue to be deployed by manufacturers at scale, it is reasonable that the safety standards are updated to reflect real life.

It is no longer about “collaborative robots”, but more about “collaborative applications”. This means proper documentation, thorough testing and sensible safety checks - not assuming that “collaborative” automatically means “safe.” Essentially, a collaborative robot with a chainsaw on the end, and no additional protection, would be deemed unsafe for human-robot collaboration.

Overall, the new regulations are positive as they are designed to:

· Protect operators.

· Clarify expectations.

· Support safer, more productive collaboration.

· Reduce ambiguity that previously slowed deployments.

These updates make it easier to design safe, collaborative applications. Nothing gets harder, it just becomes more consistent.

At RARUK Automation, we have supplied thousands of Universal Robots into UK manufacturing. Our team of automation experts are on hand to answer any questions you might have around safety, conformance and risk assessments. Additionally, our network of trusted system integrators can design and implement a complete automation system that strictly adheres to the ISO 10218:2025 guidelines.

Get started safely today. 

https://www.rarukautomation.com/