Bavarian expertise in demand worldwide: How the BMW Group is gearing up for series production of its new high-voltage batteries

Munich/Parsdorf. With the Neue Klasse, the BMW Group
is ushering in a new era of pure electric driving, starting series
production end of 2025. The high-voltage battery is a key component in
any electric vehicle. Before large-scale series production can begin,
manufacturing processes must be developed and pre-series batteries put
through their paces. This takes place at the BMW Group’s pilot plants
for high-voltage batteries in Parsdorf and Hallbergmoos and at the
Research and Innovation Centre (FIZ) in Munich. “Our pilot plants for
high-voltage batteries are strengthening Germany’s capacity for
innovation,” says Milan Nedeljković, Member of the Board of Management
of BMW AG responsible for Production. “They are laying the groundwork
for the new series plants worldwide, ensuring a smooth ramp-up of
high-voltage battery production.” To produce high-voltage batteries
for the sixth generation of BMW eDrive (Gen6), the company is
establishing five assembly sites across three continents: in
Irlbach-Straßkirchen (Lower Bavaria), Debrecen (Hungary), Shenyang
(China), San Luis Potosí (Mexico) and Woodruff (USA).

Quality is key: Consistent zero-defect
approach
For the in-house developed Gen6 high-voltage
battery, the BMW Group is implementing intelligent, state-of-the-art
production processes using the latest technologies. “For production of
our high-voltage batteries, we are pursuing a consistent zero-defect
approach,” explains Markus Fallböhmer, head of Battery Production at
BMW AG. “Highly intelligent, AI-supported quality checks are
integrated into the production process to help us achieve this.”
Because quality is key: In bodies for the Neue Klasse, the
high-voltage battery serves as a structural component (“pack to open
body”). The new cylindrical round cells are integrated directly into
the high-voltage battery (“cell to pack”). With its innovative
production processes, BMW Group’s pilot and series plants are setting
new industry standards for battery production. Examples include, among
the consistent zero-defect approach, the use of digital production
twins for tasks such as employee training, as well as leveraging
expanded AI databases to optimise supply and production logistics. All
production steps undergo seamless in-line monitoring with
comprehensive data storage, enabling maximum process stability and
continuous data-based optimisation.

Pilot plants up close: Parsdorf, Hallbergmoos and Munich
(FIZ)
The largest pilot plant for Gen6 high-voltage
batteries is located in Parsdorf, where over 350 employees have been
building initial prototypes since 2023. Since mid-2024, some of the
high-voltage batteries produced there have already been delivered to
the vehicle plant in Debrecen, Hungary, where they are installed in
test vehicles for the Neue Klasse. A pre-series plant for high-voltage
batteries is also located near Munich Airport. Since summer 2024, the
site in Hallbergmoos has been developing manufacturing technologies
for high-voltage battery assembly. Around 200 employees are working at
this small-scale battery factory. The Hallbergmoos site serves as a
model for the series production at Plant Woodruff near Spartanburg,
South Carolina, US. At the Munich Research and Innovation Centre
(FIZ), another 200 employees are manufacturing and testing prototypes
and smaller module variants of the high-voltage battery. Several
floors of the recently opened Aeroacoustics and E-drive Centre (AEZ)
are dedicated to this work.

Series launch of five battery plants in under two years

The systems and processes developed at the Bavarian
pilot plants will be rolled out to the series plants worldwide. Within
less than two years, series production will ramp up at five locations
across three continents. In line with its “local-for-local”
principle, the BMW Group has positioned its Gen6 high-voltage battery
assembly sites as close as possible to its vehicle plants. This
approach safeguards production, even in the event of unforeseen
political and economic developments. It will also strengthen existing
production sites, while preserving and creating jobs. Series
production of the BMW iX3, the first model of the Neue Klasse, will
get underway at Plant Debrecen late this year, alongside high-voltage
battery manufacturing at the same site. The launch in Debrecen will be
followed by the battery assembly plants in Shenyang,
Irlbach-Straßkirchen, Woodruff and San Luis Potosí.

How the BMW Group builds Gen6 high-voltage
batteries
The BMW Group sources battery cells for its
high-voltage batteries from leading cell manufacturers, who produce
the cells to the company’s specifications. The highest technical
standards apply. Upon receipt of goods, additional measurements – such
as voltage checks – are carried out. Next comes cell clustering, where
the battery cells are connected to coolants. This step ensures optimal
insulation and cooling of the cells. The cell clusters and cell
contact system are then laser-cleaned and welded with pinpoint
precision. The in-line inspection continuously monitors each weld seam
in real time. An innovative foaming process follows, ensuring that all
elements are protected as a mechanical unit. The foam thus guarantees
the safety, stability and durability of the high-voltage battery. The
housing is then closed, sealed and riveted. In the final assembly
step, the Energy Master – the central control unit – is installed onto
the high-voltage battery. A permanently elastic sealing adhesive is
applied to ensure a reliable seal. Finally, each high-voltage battery
undergoes a 100% end-of-line inspection to ensure quality, safety and function.

If you have any questions, please contact:

Corporate Communications


Christian Marxt
Press spokesperson, Production Network,
Powertrain and High-Voltage Batteries
Cell phone:
+49-151-601-79158
Email: Christian.Marxt@bmwgroup.com

Sandra Schillmöller
Head of Communications Production
Network BMW Group
Cell phone: +49-151-601-12225
Email: Sandra.Schillmoeller@bmwgroup.com

Media website: www.press.bmwgroup.com/deutschland
Email:
presse@bmwgroup.com