As the automotive industry accelerates toward an electrified future, the BMW Group is positioning itself at the forefront of innovation with the upcoming series production of its Gen6 high-voltage batteries. Through its pilot plants in Parsdorf, Hallbergmoos, and Munich, BMW is laying the groundwork for a smooth global rollout, marking a significant milestone in the ramp-up to Neue Klasse vehicle production.
Speaking on the progress, Milan Nedeljković, BMW AG Board Member for Production, stated, “Our pilot plants for high-voltage batteries are strengthening Germany’s capacity for innovation.” These facilities serve as critical R&D hubs, refining manufacturing processes and ensuring quality before scaling production across BMW’s international battery assembly network.
Five Plants Across Three Continents
BMW is set to begin series production of high-voltage batteries at five new plants located in Germany, Hungary, China, Mexico, and the United States by 2027. Each site is strategically placed near BMW vehicle plants to support a “local-for-local” production model, increasing supply chain resilience and reducing logistical challenges.
The first vehicle to feature the Gen6 battery will be the BMW iX3, launching from Plant Debrecen in Hungary by the end of 2025.
AI-Powered, Zero-Defect Manufacturing
According to Markus Fallböhmer, Head of Battery Production at BMW AG, BMW is adopting a zero-defect approach, utilizing AI-driven quality checks, digital twins for employee training, and advanced welding and foaming techniques. These innovations aim to enhance battery stability, durability, and safety.
Key production stages—from cell clustering with cooling systems to laser welding and AI-based inspection—are all integrated into a seamless monitoring system, ensuring that every high-voltage battery meets the company’s exacting standards.
Innovation Hubs in Bavaria
- Parsdorf: The largest Gen6 pilot plant, where over 350 employees are building initial prototypes.
- Hallbergmoos: Near Munich Airport, focusing on process development with 200 staff; acts as a blueprint for BMW’s new US facility in Woodruff, South Carolina.
- Munich (FIZ): The Research and Innovation Centre is testing modular variants and housing BMW’s Aeroacoustics and E-drive Centre.
Shaping the Future of E-Mobility
From cutting-edge cell-to-pack integration to robust structural design, BMW’s Gen6 batteries are redefining EV performance. These innovations are critical for the success of the Neue Klasse, the company’s visionary electric vehicle platform.
This large-scale global rollout not only underscores BMW’s technological leadership but also reinforces its commitment to sustainable production, job creation, and energy-efficient mobility.
