BMW begins making 6th-gen EV batteries in China with 20% higher energy density

BMW Group has begun series production of its sixth-generation high-voltage batteries in Shenyang, China, to power future Neue Klasse electric vehicles built in the country. The new technology offers up to 30 percent longer range and faster charging compared with the previous generation.

Shenyang becomes the third production location in BMW’s global Gen6 battery network, following Debrecen in Hungary and Irlbach-Straßkirchen in Germany.

Manufacturing batteries near vehicle plants shortens transport routes and supports local supply as the automaker expands production of its latest electric-vehicle technology.

“The high-voltage battery is a key component of our all-electric vehicles and one of the BMW Group’s most important technologies for the future,” said Dr. Raymond Wittmann, BMW AG’s board member responsible for Production.

New cells offer higher energy density

The Gen6 batteries use newly developed cylindrical cells with more than 20 percent higher energy density than the previous cell generation. BMW mentioned that the technology also delivers up to 30 percent faster charging and longer range.

A cell-to-pack design integrates the cylindrical cells directly into the battery housing, removing the conventional module level. This arrangement makes better use of the available installation space and allows BMW to adapt the battery for different vehicle models.

The battery also incorporates BMW’s Energy Master, a central control unit mounted directly on the high-voltage pack. It brings together essential power-supply and battery-management functions.

The Shenyang batteries are intended for China-built Neue Klasse models, making local battery manufacturing a key part of the company’s regional vehicle production plans.

Battery network expands across markets

BMW’s Gen6 manufacturing strategy places battery assembly close to the vehicle factories it supplies. The company says this approach supports stable supply and strengthens the resilience of its production network.

Battery assembly facilities in Woodruff, United States, and San Luis Potosí, Mexico, are also preparing to begin series production in the coming months.

All locations operate under common production, quality, and safety standards and contribute regional manufacturing and supplier expertise.

“Production in Shenyang exemplifies our global approach: We manufacture locally, efficiently and close to our markets, in line with uniform global standards and the highest quality,” Wittmann said.

Laser welding meets digital quality checks

Production starts with cell inspections before the cells are joined with cooling units to form clusters. Following laser cleaning, those clusters and the cell contact system are precision-welded together.

A specialized foaming process then bonds the components into a single mechanical unit, contributing to the battery’s safety, stability, and longevity.

Workers and production equipment complete the housing closure, sealing, and riveting before the Energy Master is installed.

Digital quality controls accompany the manufacturing process. Production data is captured and analyzed throughout assembly, while digital twins, data analytics, and AI-supported inspections help identify deviations early and maintain traceability.

Inline inspection systems monitor laser-welded joints in real time. Every completed battery then undergoes comprehensive end-of-line testing for quality, safety and functionality.

With Shenyang now producing Gen6 batteries, BMW has established a local source for the energy systems underpinning its China-built Neue Klasse vehicles.

Source: https://interestingengineering.com/transportation/bmw-starts-gen6-battery-production-in-china