Over the past decade, industrial robots have evolved from specialized, hard-to-program machines into adaptable, software-driven assets at the core of modern manufacturing. Researchers from the Polytechnic University of Milan, working with Trend Micro’s forward-looking threat research team, have examined how this transformation is reshaping operational technology (OT) environments and the security challenges that follow. As Marcello Pogliani noted, the ease of programming has solidified robots as “the heart of smart manufacturing and so-called Industry 4.0 paradigm shift.”
A single robotic arm can be outfitted with a range of manipulators—pliers, laser engravers, cutters, or welding arcs—allowing it to perform tasks from precise pick-and-place operations to hazardous duties like welding, lifting heavy loads, or handling biohazards. This versatility removes debate over whether certain tasks should be automated; instead, decision-makers focus on where, when, and how to allocate resources, whether in training personnel to program robots or in deploying more robotic systems. The trajectory for 2021 and beyond points toward accelerated adoption and increasingly sophisticated programming software.
Yet, the security landscape for industrial robots lags behind their technological capabilities. Federico Maggi emphasized that IT software development has matured over decades, with automated pipelines that integrate testing, including security checks, into every stage of deployment. Common vulnerabilities are often detected early, thanks to established tools and a culture of security awareness. In contrast, many OT software developers still operate under the assumption that “everything is airgapped so there’s nothing to worry about,” a mindset increasingly at odds with interconnected manufacturing systems.
Industrial robots inherit legacy architectures, often lacking the protections found in modern computing platforms such as managed, memory-safe programming languages. This leaves them susceptible to memory corruption vulnerabilities and other low-level exploits. According to Maggi, it may take another decade for OT software development to reach the maturity level of IT counterparts. However, market forces are pushing in the opposite direction: the drive to simplify OT software development shortens the cycle from design to deployment, increasing the risk that untested or insecure code will reach production environments.
The challenge is compounded by the pace of industrial automation. As robots become more integral to production lines, downtime for thorough security vetting is often seen as a competitive disadvantage. This tension between operational efficiency and cybersecurity rigor creates fertile ground for vulnerabilities to persist. Without systematic adoption of both automated and manual security checks, the probability of security flaws slipping into active systems remains high.
When asked how operations can better safeguard industrial robots, Pogliani stressed the importance of visibility: “Knowing what software is running on each machine, including robots, is a good start.” He cautioned against rushing toward the latest security products without a clear process. “Security does not start from installing a shiny box: security is a process, and a good process needs good data.” In industrial automation, the true lifeblood is not the hardware but the software controlling it. Comprehensive inventories of software assets form the foundation for any effective OT security strategy.
Network segmentation remains a baseline requirement, isolating critical systems to limit the spread of potential intrusions. However, as Pogliani pointed out, this is now considered fundamental practice. The emerging priority is maintaining an accurate, up-to-date map of the OT software environment. With that knowledge, organizations can design targeted security measures that address the specific vulnerabilities of their robotic systems.
The convergence of robotics, software, and networked manufacturing demands a shift in mindset. Security for industrial robots can no longer rely on physical isolation or legacy assumptions. As Industry 4.0 accelerates, the balance between innovation speed and system resilience will define the operational safety and reliability of the next generation of automated production.