BMW Group has started series production of its sixth-generation (Gen6) high-voltage batteries in Shenyang, China, ahead of their introduction in locally manufactured Neue Klasse electric vehicles.
The facility is BMW’s third Gen6 battery production location worldwide, following Debrecen in Hungary and Irlbach-Straßkirchen in Germany.
The new battery technology uses cylindrical cells offering more than 20% higher energy density than BMW’s previous generation, with charging speeds and driving range improving by up to 30%.
BMW has also adopted a cell-to-pack design, integrating the cells directly into the battery housing rather than assembling them into conventional modules first.
This improves space utilisation and allows the battery packs to be adapted to different vehicle designs.
Another component is BMW’s in-house-developed Energy Master, a central control unit mounted directly on the battery that manages electrical supply and battery functions.
BMW board member for production Dr Raymond Wittmann said the Shenyang milestone marked further progress in rolling out Gen6 battery technology across the company’s global manufacturing network.
BMW’s strategy centres on producing batteries close to vehicle assembly plants to improve efficiency, reduce transport requirements and strengthen supply reliability.
Two additional facilities, in Woodruff, United States, and San Luis Potosí, Mexico, are scheduled to begin series production in the coming months.
At Shenyang, battery assembly involves automated cell inspection, laser welding and specialised bonding processes before the Energy Master is installed.
Digital manufacturing systems use data analytics, digital twins and AI-assisted inspections to monitor production and identify potential defects.
Completed batteries undergo final safety, functionality and quality checks before being supplied for vehicle assembly.
