BMW builds five new battery assembly plants for ‘Neue Klasse’

The BMW Group is significantly expanding its production network for the next generation of high-voltage batteries. Across the globe, the principle of ‘local for local’ will apply, so plants will be built in Germany, Hungary, China, Mexico, and the US.

“Close connection of battery production with vehicle production is part of our strategy,” explains Markus Fallböhmer, Senior Vice President of Battery Production at BMW AG. “This helps the BMW Group increase the resilience of its production.”

For the ‘Neue Klasse’

The official press release states, “The ‘Neue Klasse’ will be the first to incorporate the all-new cylindrical cells. These represent a technological leap by the BMW Group, offering vastly improved energy density, charging times, and range.”

They will be assembled in new facilities as close as possible to vehicle plants, in keeping with the principle of ‘local for local’. Assembly plants for sixth-generation high-voltage batteries are currently under construction in Irlbach-Strasskirchen (Lower Bavaria), Debrecen (Hungary), Woodruff (near Plant Spartanburg in the US), Shenyang (China), and San Luis Potosí, Mexico.

“With the ‘local for local’ approach in place, production can continue even when unexpected political or economic events occur. In addition, short distances between battery and vehicle plants will reduce car production’s carbon footprint. The BMW Group is also upgrading its existing sites,” BMW stresses.

Battery expertise concentrated in Parsdorf and Munich

Prototype battery cells like the ones in the Neue Klasse, launching in 2025, are already being made at the BMW Group’s Cell Manufacturing Competence Centre (CMCC) in Parsdorf, just east of Munich.

The CMCC was built to complement the Battery Cell Competence Centre (BCCC) in the north of the city, where development work is carried out. The CMCC scales up the best product for series production.

“Product and process are uniquely interlinked by the close collaboration across divisions, between Development, Purchasing and Production. The BMW Group operates further pre-series plants and pilot lines for future high-voltage batteries in Munich and the nearby towns of Parsdorf and Hallbergmoos,” says the press release.

Debrecen first

The first Neue Klasse vehicles will be produced at the BMW Group’s new plant in Debrecen (Hungary) starting in 2025. High-voltage battery and vehicle manufacturing will launch in parallel. The final buildings are currently being completed and will be handed over to the technologies by the end of the year.

The BMW Group will also manufacture high-voltage batteries for Neue Klasse models in Germany, specifically in Irlbach-Straßkirchen, Lower Bavaria. The new facility will supply sixth-generation high-voltage batteries to German car plants.

From 2026, BMW Brilliance Automotive (BBA) will also manufacture Neue Klasse vehicles in Shenyang, China. The sixth-generation high-voltage batteries required for the cars will also be manufactured locally here. The production hall was completed in November 2023 after only 21 months of construction.

At San Luis Potosí in Mexico, additional production capacity is being established for the Neue Klasse series production, starting in 2027. Construction of the new high-voltage battery assembly plant started in May 2024 and will comprise over 80,000 square meters of production space when completed.

Finally, BMW Group Plant Woodruff in the US. will consist of a technology building, ancillary structures, an energy center, a staff restaurant, a fire department, and a Talent Campus. When construction is completed in 2026, Woodruff will assemble high-voltage batteries for fully electric cars made in nearby Plant Spartanburg.