Automation Fair 2025, Rockwell Automation’s flagship industrial automation tradeshow, wrapped up on Thursday, November 20. For four days, industrial professionals from around the world converged on Chicago, to explore the latest innovations, connect with technology leaders and learn from industry experts driving the next wave of industrial transformation.

This year’s agenda delivered high-energy keynotes, targeted summits, hands-on lab and deep-dive technical sessions. The expo floor stayed busy as Rockwell Automation and its extensive PartnerNetwork demonstrated advances in robotics, intelligent material handling, industrial AI, digital engineering tools, process automation and cybersecurity.

Overall, it was a dynamic and future-focused week at one of the industry’s most influential events. And if the week proved anything, it’s that automation continues to evolve at a pace that challenges and motivates engineers everywhere.

Here are five things we learned this week at Automation Fair 2025

Software-defined automation is the next big thing

If there was a true overarching theme, it was that automation is no longer the destination. Instead, it is autonomy.

Here, software systems are not just informing the decisions of humans — they are making them, thanks to advanced analytical and machine learning tools. And with more experience, these algorithms are making them better and faster than ever.

Then, those platforms drive actual process or workflow changes by issuing new commands to physical hardware, like robots or conveyors.

“I would like to encourage everyone to ground this revolution of digital operations into a digital reality,” said Cyril Perducat, CTO of Rockwell Automation, during a keynote address.

This has been termed software-defined automation, and it follows patterns seen in other key industries and technologies, like software-defined radio or software-defined vehicles. As technologies mature and digital and physical interfaces become more common, this was always the promised land.

Truthfully, few manufacturers are there today, but it gets closer each day because there are so many ways software can influence manufacturing — be it in simulation, networking, big data collect and analysis, remote access or so much more.

Too often, manufacturers prioritize the wrong cyber risks

Manufacturers are still vulnerable, but not due to a lack of investments. Instead, too often organizations are prioritizing the wrong investments. Strong security platforms are vital, but only when they directly support customer outcomes, risk reduction and operational performance. When they don’t, they overcomplicate the IT/OT environments and fail to see a recognizable return on their investment.

“Understanding your risk and viability and managing that is absolutely critical,” said Maria Else, global product manager for industrial cybersecurity at Rockwell.

There must also be an understanding that a diligent cybersecurity program won’t stop every attack, but it will give you effective strategies to minimize risk and damage from inevitable intrusions.

“Bringing those various things can help our customers come to grips with the problem and when they are attacked,” added Else.

These ideas will become even more critical in 2026, when European manufacturers face compliance with the Cyber Resilience Act. More regulations, in different markets, are likely to follow.

Optimism about AI is still high

Implementing AI across manufacturing has been uneven. And at times, the hype has outweighed its real value. But it remains a critical tool for driving efficiency — and the technology grows immensely each year.

“Just in the field of AI, five years ago you couldn’t imagine the pattern we see now,” said Perducat.

However, manufacturers should avoid AI as a standalone novelty or overemphasizing flashy approaches, such as simply moving software around via APIs. Instead, AI should be viewed as another tool that can drive tangible value when applied thoughtfully. Operators should select AI tools and applications that are truly appropriate for the challenges at hand. This will have wide impact on software-defined automation.

“Software-defined automation, artificial intelligence, and the physical embodiment of AI — this is the technical foundation of the revolution in digital operations,” said Perducat.

Manufacturers are getting hands-on in education

Across several press conferences and discussions, another thing became clear: the next generation of engineers will need different skill sets than the ones of today. That’s not new in and of itself.

However, manufacturers and industry leaders are taking ownership of this by working with more educational institutions and helping develop lessons and experience for fledgling industry professionals.

Students from Purdue Polytechnic Institute were on hand displaying their customized bobblehead machine, driven by Rockwell’s CompactLogix PLCs and FactoryTalk HMIs. Attendees selected bobblehead features and watched in real time as pick-and-place gantries assembled the bobbleheads on a rolled-chain conveyor system.

Additional students from other schools and the FIRST Robotics League made for the largest educational wing in recent Automation Fair history. Kristi Scarpone, senior director of business development for FIRST, was very grateful for Rockwell's partnership.

Safety has gone native

Safety has never been an afterthought, but equipment that monitors or enforces it often requires new investment, maintenance and monitoring. And of course, it is impossible to take the human element out of personnel safety.

However, many technologies displayed at the show offer novel ways to keep workers safe. Grace Technologies showed off wearables that alert workers in the presence of energized equipment. Festo USA displayed its new safety valve terminals for process applications. Itoh Denki showcased its low-voltage, safe-to-touch roller conveyors. Attendees mingled with cobots that elegantly packaged, assembled and picked products with delicacy.

And of course, one of Rockwell’s star products, ControlLogix 5590, is compliant with SIL 2 (Safety Integrity Level 2) per IEC 61508/62061 and PL d (Performance Level d) per ISO 13849. Users won’t need extra CPUs, controllers or hardware to handle typical machine-safety tasks like emergency stops or light curtains.