Here, BMW builds the next generation of high-voltage batteries

With the Neue Klasse, the BMW Group is ushering in a new era of purely electric driving. A key factor for its success is the production of high-performance high-voltage batteries. Therefore, the company from Munich is massively expanding its production network for the next generation of high-voltage batteries.

"For the sixth generation of our high-voltage batteries, we are establishing five locations on three continents," reports Milan Nedeljković, BMW AG’s Board Member for Production.

Thus, the BMW Group is globally adhering to the "Local for Local" principle.

"The close integration of battery manufacturing with vehicle production is part of our strategy," explains Markus Fallböhmer, Head of Battery Production at BMW AG. This increases the resilience of the BMW Group's production.

Newly developed cylindrical cells

The Neue Klasse models will be the first to use newly developed cylindrical cells. According to BMW, this marks a significant technological leap with substantial improvements in energy density, charging speed, and range. The assembly of these cylindrical cells into high-voltage batteries will take place in new production facilities in Irlbach-Straßkirchen (Lower Bavaria), Debrecen (Hungary), Shenyang (China), San Luis Potosí (Mexico), and Woodruff near Spartanburg (USA). This approach ensures production even in the face of unforeseen political and economic events. Additionally, the existing locations are being strengthened. The shorter distances reduce the CO₂ footprint in vehicle production.

Debrecen Plant starts in 2025

In the new Debrecen plant, the first vehicles of the New Class will be manufactured starting from 2025. High-voltage battery and vehicle production will commence simultaneously. In autumn 2023, the training center was opened at the Debrecen plant. The communication center was occupied in February 2024. While numerous employees are already working at their office jobs on site, production employees are also preparing for their future roles in Debrecen within the global BMW production network. This is how the company aims to ensure a smooth start of pre-series production – as well as the series launch in the second half of 2025. Currently, the last buildings are being completed and handed over to the technologies by the end of the year.

High-voltage batteries from Lower Bavaria

BMW will also manufacture high-voltage batteries in Germany for the models of the New Class – specifically at the Irlbach-Straßkirchen site in Lower Bavaria. From here, German vehicle plants will be supplied with the sixth generation of batteries in the future. In April 2024, the automotive group received the construction permit for establishing the assembly plant. The first column was erected at the end of June 2024. By the end of the year, the production building is expected to be completed with facade and roof. In September 2023, the citizens of Straßkirchen voted with a clear majority in favor of the BMW Group setting up its plant in a referendum.

Production of the New Class in China from 2026

From 2026, BMW Brilliance Automotive (BBA) will produce New Class vehicles in Shenyang (China). The required high-voltage batteries of the sixth generation will also be manufactured locally. In November 2023, the production hall was completed in just 21 months, and the installation of the equipment began in March 2024. In preparation for the start of the New Class, BMW has established the largest research and innovation network outside of Germany with locations in Beijing, Shanghai, Shenyang, and Nanjing.

New Class in Mexico from 2027

For the series start of the New Class in 2027 in San Luis Potosí, Mexico, additional production capacities will be created on the factory premises. The new high-voltage battery assembly celebrated its construction start in May 2024 and will cover over 80,000 m² upon completion. In addition to integrating the battery assembly, further adjustments will be made at the San Luis Potosí plant: the body shop will expand to a total area of more than 90,000 m², and the assembly and logistics areas will be expanded by nearly 10,000 m². BMW will be the first premium OEM to manufacture fully electric vehicles and high-voltage batteries in Mexico. Additionally, there are plans to expand the photovoltaic systems within the plant and thereby double the output from renewable energy. This is intended to generate more than 20% of the current power demand directly on the factory premises in the future.