BMW Group is ready to usher in a new era in electric mobility with the introduction of the Neue Klasse, marking a milestone in the production of electric vehicles.
The key to the success of this transition lies in the production of the powerful sixth-generation high-voltage batteries, which is why the company is significantly expanding its global production network. “We are establishing five plants on three continents to produce our sixth-generation high-voltage batteries,” said Milan Nedeljković, Member of the Board of Management for Production at BMW AG. This expansion follows the principle of “local for local,” ensuring that battery production is closely linked to vehicle production to increase operational resilience.
Integrated battery and vehicle manufacturing
The Neue Klasse will be the first range of vehicles to benefit from the latest cylindrical cells, a technological breakthrough that promises significant improvements in energy density, charging times and range. These batteries will be produced in new facilities located close to vehicle production plants, thus reducing environmental impact and increasing efficiency. State-of-the-art assembly plants for the sixth-generation high-voltage batteries are currently being built in Irlbach-Strasskirchen (Lower Bavaria), Debrecen (Hungary), Woodruff (near Spartanburg in the United States), Shenyang (China) and San Luis Potosí (Mexico). This strategy not only improves sustainability, but also ensures production continuity in the event of unforeseen geopolitical or economic events.
Debrecen: The Starting Point of the Neue Klasse in 2025
The new plant in Debrecen, in Hungary, will be the first to produce Neue Klasse vehicles, starting in 2025. The production of the high-voltage batteries and vehicles will start in parallel, ensuring a coordinated and successful launch. Already operational since autumn 2023, the training centre in Debrecen and the communication centre, active since February 2024, are preparing a large number of employees for the future of production. The regular start of pre-series production is planned for the second half of 2025, with the final work on the buildings being completed.
Production in Germany: Irlbach-Straßkirchen
BMW Group chooses Lower Bavaria for the production of high-voltage batteries for Neue Klasse models. The new plant in Irlbach-Straßkirchen will supply these batteries to German car plants. Planning permission was obtained in April 2024, and construction work began in June 2024. The plant is scheduled to be completed by the end of the year, with the facades and roof installed. The local community supported the arrival of the BMW Group with a clear majority in a referendum held in September 2023.
Shenyang: Chinese Neue Klasse production from 2026
From 2026, production of the Neue Classe will also be launched in China, at the BMW Brilliance Automotive (BBA) plants in Shenyang. The sixth-generation high-voltage batteries will be produced locally to support vehicle production. Construction of the production hall was completed in November 2023, after just 21 months of construction. Installation of the plant and machinery began in March 2024. To prepare for the launch of the Neue Klasse, the BMW Group has established its largest research and development network outside Germany, with facilities in Beijing, Shanghai, Shenyang and Nanjing.
Expansion into Mexico: San Luis Potosí
Production of the Neue Klasse will begin in San Luis Potosí, Mexico, in 2027. Construction of the new high-voltage battery assembly plant began in May 2024 and, once completed, will comprise more than 80,000 square meters of production space. The expansion does not only concern battery assembly: the plant’s body shop will grow to more than 90,000 square meters, while vehicle assembly and logistics space will increase by almost 10,000 square meters. The BMW Group is the first premium OEM to produce fully electric cars and high-voltage batteries in Mexico. In addition, the company plans to expand its photovoltaic systems, doubling the energy generated by photovoltaics to meet more than 20 percent of the plant’s energy needs.
United States: Woodruff and Spartanburg
Electromobility is also making progress in South Carolina, where the BMW Group is building a new plant in Woodruff. This site, which will cover an area of around 93 hectares, will include a technology building, ancillary facilities, an energy center, a staff restaurant, a fire station and a Talent Campus. The plant will create more than 300 new jobs and will assemble high-voltage batteries for electric cars produced at the nearby Spartanburg plant. The groundbreaking ceremony for the Woodruff training center took place in June 2023, marking the start of a project that will be completed in 2026.
Innovation and expertise in Germany: Parsdorf and Munich
The BMW Group has concentrated its battery expertise in the Cell Manufacturing Competence Centre (CMCC) in Parsdorf near Munich. This is where battery prototypes such as those for the Neue Klasse are produced. The CMCC complements the Battery Cell Competence Centre (BCCC) in the north of Munich, where development work takes place. This close cooperation between development, purchasing and production ensures that the BMW Group can prepare the best possible product for series production. Further pre-series plants and pilot lines for future high-voltage batteries are located in Munich and in nearby Parsdorf and Hallbergmoos.
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