Woodruff, South Carolina, USA. In December, the new
BMW Group Plant Woodruff will begin series production of high-voltage
batteries for the new fully-electric BMW iX5. As part of the vehicle’s
world premiere, the company offered a first glimpse of its
state-of-the-art manufacturing facilities. With AI-supported
production processes, digital twins and virtual reality applications,
the new plant is setting industry standards for the assembly of
high-voltage batteries.
Site strengthens electromobility in the US and footprint in
South Carolina
“Plant Woodruff plays a key role in the ramp-up of electromobility in
the US,” said Raymond Wittman, member of the Board of Management of
BMW AG responsible for Production. “With our Gen6 high-voltage
battery, we’re not only taking a major technological leap – we are
also setting new standards in production. In Woodruff, we are
combining cutting-edge processes, artificial intelligence and the
expertise of our employees to create a production facility designed
for the highest quality.”
“With Plant Woodruff, we are further expanding our footprint in South
Carolina and strengthening the close integration of battery and
vehicle production,” said Robert Engelhorn, President and CEO of BMW
Manufacturing Co., LLC. “This creates the ideal foundation for the
next generation of fully electric BMW X models assembled at Plant Spartanburg.”
Intelligent production for maximum quality
The BMW Group has established state-of-the-art, intelligent and
efficient production processes for its in-house developed
sixth-generation (Gen6) high-voltage battery. The new cylindrical
round cells are integrated directly into the high-voltage battery,
based on the “cell-to-pack” principle. All production steps are
continuously monitored inline and comprehensively documented in real
time. In-house developed AI assistants and agents analyse this data
and, together with more than 300 employees and 250 robots at Plant
Woodruff, ensure the zero-defect battery production. At the same time,
the extensive use of artificial intelligence enhances Overall
Equipment Effectiveness (OEE) in production. Well before
commissioning, digital twins of production and virtual reality
applications support planning and employee training.
Training in a virtual factory
All production staff at Plant Woodruff complete a VR training program
developed on site. Within a virtual factory, they can practice real
manufacturing operations under realistic conditions. This virtual
environment replicates the plant’s production lines in meticulous
detail, requiring only a set of VR goggles and a PC. The training
helps employees develop an understanding of relevant processes and
builds confidence in operating the equipment before using the actual
manufacturing systems for the first time.
Just three years from start of construction to series production
Following the official groundbreaking in June 2023, construction of
the new plant began in September 2023. In September 2024, while
construction was still under way, installation of the manufacturing
equipment commenced. Preparations for production started in summer
2025, and the first test and pre-series batteries have been rolling
off the assembly line since then. The series launch is scheduled for
December 2026. “Plant Woodruff demonstrates how quickly we can scale a
new battery concept to industrial production,” said Rich Everly, Vice
President of Production at BMW Group Plant Woodruff. “The key factor
is the synergy between a skilled and dedicated team and the continuous
exchange of experience within the production network.”
Gen6 battery cells with reduced carbon footprint
The Gen6 battery cells used in the BMW iX5’s high-voltage battery
include a high proportion of secondary materials in the cobalt,
lithium and nickel content. Renewable energy is also used in the
production of anode and cathode materials, as well as in cell
manufacturing. Compared with the Gen5 cell used in the BMW iX, CO₂e
emissions have been reduced by around 28 percent per watt-hour. Plant
Woodruff does not use any fossil fuels during normal operations, while
the site’s industrial trucks are powered by hydrogen.
Global production strategy: local for local
Installation of the Gen6 high-voltage batteries takes place at five
new production facilities, which the BMW Group is building close to
its vehicle plants, in line with its “local for local” principle. In
addition to Woodruff, state-of-the-art high-voltage battery assembly
plants are also being built in Irlbach-Straßkirchen (Lower Bavaria),
Shenyang (China) and San Luis Potosí (Mexico). The latest generation
of high-voltage batteries has been in series production in Debrecen,
Hungary, since October 2025. This “local for local” approach
strengthens regional infrastructure and existing facilities and helps
secure jobs. The global production network for high-voltage batteries
benefits from close collaboration between the German pilot plants and
series production facilities worldwide.
How the BMW Group assembles its Gen6 high-voltage batteries
The BMW Group sources battery cells for its high-voltage batteries
from leading cell manufacturers. The highest technical standards
apply. Upon receipt of goods, additional measurements – such as
voltage checks – are carried out. Next comes so-called cell
clustering, where the battery cells are connected to coolers. This
step ensures optimal insulation and cooling of the cells. The cell
clusters and cell contact system are then laser-cleaned and welded
with pinpoint precision. The inline inspection continuously monitors
each weld seam in real time. An innovative foaming process follows,
ensuring that all elements are protected as a mechanical unit. The
hardened foam guarantees the safety, stability and durability of the
high-voltage battery. The housing is then closed, sealed and riveted.
In the final assembly step, the Energy Master – the central control
unit – is installed onto the high-voltage battery. A permanently
elastic sealing adhesive is applied to ensure a reliable seal.
Finally, each high-voltage battery undergoes a 100% end-of-line
inspection. From Woodruff, the high-voltage batteries are transported
to Plant Spartanburg, located just 15 miles away.
The BMW iX5’s high-voltage battery: 800-volt, with high energy content
The first battery-electric BMW iX5 is based on sixth-generation
BMW eDrive technology, featuring round cells and 800-volt technology.
With an available energy content of 144 kWh in the US and 141 kWh in
the EU (net), the BMW iX5 60 xDrive boasts the largest high-voltage
battery of any fully-electric BMW model to date. Propulsion is
provided by e-drives on both the front and rear axles, and by the
electric BMW xDrive all-wheel drive.