CMCC Parsdorf: BMW starts battery cell production and aims to consolidate know-how

No large-scale series production, but delving deep into the key technology of batteries is the goal: The Munich-based automobile manufacturer BMW has, as repeatedly announced, started operations at its competence center for battery cell production in Parsdorf, east of the state capital, to also underscore its claims regarding the key component of the electric car era. The investment of 170 million euros over the last two and a half years since the project decision is expected to pay off quickly through the acquisition of valuable know-how that directly flows into product improvement, according to a responsible person speaking to VM. Even the previous cell research and development at the headquarters in Munich has provided important insights for optimizing the battery cells of Generation 5.

There will be no "Parsdorf Batteries" in the vehicles

The so-called battery cell samples manufactured at the site are 95 millimeters high, cylindrical, and have a diameter of 46 millimeters. Batteries in this format are set to be used from 2025 in the models of the so-called "New Class," which was first shown as a concept at the IAA. However, under no circumstances will these come from "Parsdorf production," which amounts to about 1,000 to 2,000 batteries or one million cells (0.1 gWh), but rather from the respective suppliers who are currently being determined.

So far, CATL cells have been used by the manufacturer. The "Cell Manufacturing Competence Center" (CMCC) in Parsdorf is not intended to represent series production but to make the manufacturer fit for the ramp-up of electromobility, claiming nothing less than a "leading role in battery cell technology" for the company. Based on the findings in production, a "specification sheet" for the supplier is to be created, with which the new battery design will be developed and built in close cooperation on a separate and dedicated line, as emphasized by the Munich company.

"With the competence center for battery cell production, we are strengthening innovation power in Germany. This makes an important contribution to the technological leap forward of the New Class," explains Milan Nedeljković, BMW AG's production director.

In this context, he called for a reliable legal framework and a reduction in bureaucracy, improvements in infrastructure regarding digitization and sustainable energy, and a dense network of education and research as a foundation. Especially in HV battery technology, major leaps are expected to be quickly transferred into industrialization. The battery plays a key role in the mobility of the future. The interaction between research, politics, and companies works especially well in Germany, which is why investment is being made at this location.

Germany does not have its future behind it

Germany and Europe do not have their future behind them, but rather need to highlight their strengths more clearly in global competition. BMW ranks 3rd in patent applications in the field of batteries, which are now to be bundled in Parsdorf. It is about a "technological leap forward," said Nedeljković. Although there is a deliberate decision not to enter large-scale series production, there is a deep dive into technology, combining development in Munich and cell production in Parsdorf.

The new sample production of battery cells in Parsdorf marks the next logical step in our battery cell strategy, states Frank Weber, BMW AG's development director. The competence center for battery cell production is the perfect complement to our already existing battery cell competence center in northern Munich.

"While development takes place there, we scale the best product towards series process in Parsdorf. Thanks to cross-departmental collaboration, we link product and process," Weber further outlines.

The Parsdorf CMCC enables the BMW Group to fully depict the value creation processes of the cell. The responsible persons speak of 100 parameters and 3,000 effect interrelations in a cell to illustrate the level of complexity. Through this know-how, the company aims to set benchmarks in production, quality, performance, cost, and ecology, which it will implement in close collaboration with its partners for series production of the battery cells. The ramp-up of what is proudly referred to as the already sixth generation of BMW electric drives, as well as the development of all-solid-state batteries (ASSB), is to be supported.

About 80 employees work in the 15,000-square-meter CMCC. The investments in the competence center for battery cell production amount to around 170 million euros. The Federal Ministry for Economic Affairs and Energy and the Bavarian Ministry of Economic Affairs, Regional Development, and Energy support the project within the framework of the European funding process IPCEI (Important Projects of Common European Interest).

Recycling at CMCC: Keeping Materials in the Loop

Raw materials are among the significant cost factors in cell manufacturing, which is why there is a commitment to an "efficient and responsible use of starting and carrier materials," characteristic of Munich, where ecological and economic benefits are paired. At the site, experiences will be gathered in all processes to optimize resource use. Thus, the residual materials generated during the production process are collected, sorted, and reintroduced into the cell manufacturing cycle. Besides manufacturing, the reuse of materials and components of the entire battery after its first use in a vehicle plays a crucial role.

At the Munich Battery Cell Competence Center (BCCC), the first battery cells were made from 100% recycled or secondary cathode materials (battery grade) and tested with the most modern characterization methods, as they proudly point out. Additionally, cell manufacturers already supply battery cells containing portions of secondary raw materials (such as nickel), derived from various old battery sources (including production waste). The long-term goal is the comprehensive reuse of the raw materials in recyclable high-voltage batteries.

Path to the Cell: Production in Pilot Manufacturing

Cell manufacturing starts with electrode production. Here, the base material, including graphite for the anode and nickel oxides for the cathode, is dosed and mixed with binders and solvents in a precisely measured ratio. This creates the so-called "slurry." Ultra-thin metal foils are then coated with it and compressed after drying. This process is known as calendaring in technical jargon. It demands the highest precision, as the manufacturer describes: The foil is only a few micrometers thick, thinner than the threads of a spider web. The coating is within the micrometer range. In cell assembly, the coated foils, technically referred to as calendered electrodes, are wound with the separator into so-called "jelly rolls" and placed into the cell housing. The cells are then filled with electrolytes, charged for the first time, and finally tested for their function and quality.

CMCC Parsdorf: A Building Focused on Ecology

The CMCC building also aims to meet high ecological standards, such as in emission protection, where all requirements and guidelines are met. Additionally, the area is operated "fossil-free" using renewable electricity, including through photovoltaic systems on the roof. The building is also supplied with renewable heat generated via groundwater and air source heat pumps.

The Sixth Generation: New Cell Format, Advanced Cell Chemistry

The battery cell is responsible for key characteristics of electric vehicles: range, performance, and charging time, as the manufacturer points out. With the new, specifically designed BMW round cell tailored to the e-architecture of the models in the Neue Klasse, it should be possible to significantly increase the range by up to 30 percent (according to WLTP) in the highest range model. The new round cells have a uniform diameter of 46 millimeters and come in two different heights of 95 millimeters and 120 millimeters. Compared to the prismatic cells of the fifth battery cell generation, the nickel content on the cathode side is increased and the cobalt content is simultaneously reduced in the round cells of the sixth generation, as specified. On the anode side, the silicon content is increased.

As a result, the volumetric energy density in the cell increases by more than 20 percent. The energy storage, drivetrain, and charging technology of the Neue Klasse will feature an increased voltage of 800 volts, according to the announcement. Among other things, this will optimize the input of energy at DC fast-charging stations. There, with a current of up to 500 amperes, a significantly increased charging performance can be achieved, reducing the required time to charge from ten to 80 percent by up to 30 percent, promise the Munich-based company.