Woodruff, South Carolina – July 20, 2026… 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 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 analyze 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 cylindrical cells and 800-volt technology. With an available energy content of 144 kWh, the BMW iX5 60 xDrive boasts the largest high-voltage battery of any fully-electric BMW model to date.

                                      # # #

BMW Group in the U.S.

BMW Group began operations in the U.S. over 50 years ago. In addition to the sales, marketing, and distribution of BMW, MINI, Rolls-Royce, and BMW Motorrad vehicles, BMW Group’s business in the U.S. spans 30 locations in 12 states including BMW Group Financial Services, BMW Manufacturing, Designworks, BMW Technology Office USA, and BMW i Ventures. The company’s U.S. plant in South Carolina is the largest single BMW production facility in the world and the global center of competence for BMW Sports Activity Vehicles. The BMW Group sales organization is represented by a nationwide network of 359 BMW retailers, 139 BMW motorcycle retailers, 104 MINI passenger car dealers, and 38 Rolls-Royce Motor Car dealers. Taken together, BMW Group’s business activities in the U.S. provide and support over 120,000 jobs and contribute more than $43.3 billion to the U.S. economy annually.

For more information about BMW Group’s business and products in the U.S., please visit: PressClub USA.

• Export Value from South Carolina Plant is $9 Billion.
• Nearly 200,000 BMWs Exported to Nearly 120 Countries.
• From 2014 to 2025, BMW’s Export Value Totaled More Than $113 Billion.

Spartanburg, S.C. – March 5, 2026… BMW Manufacturing has confirmed that it led the nation in automotive exports by value during 2025, according to data released by the U.S. Department of Commerce. Last year, the South Carolina plant exported nearly 200,000 BMW X models with a total export value of $9 billion. Additionally, from 2014 – 2025, Plant Spartanburg exported nearly 3 million vehicles with an export value of $113 billion.

The BMWs assembled in Spartanburg, South Carolina, were primarily exported through the Port of Charleston, SC, and through four additional ports: Brunswick, GA; Jacksonville, FL; Everglades, FL; and Baltimore, MD. More than 14,000 BMWs were also exported via rail.

“Free trade and open markets enable growth and prosperity. Our plants — and above all the strong supplier networks in each respective region — benefit from this,” said Milan Nedeljković, Member

of the Board of Management of BMW AG responsible for Production.

“BMW Manufacturing is proud to be the largest automotive exporter by value in the United States, a distinction that underscores our commitment to both the state of South Carolina and the nation’s economic strength,” said Dr. Robert Engelhorn, president and CEO of BMW Manufacturing. “Our exports play a crucial role in supporting a favorable balance of trade, which is essential for sustained economic growth.

During 2025, associates assembled 412,799 BMW X models. This marks the third-highest total in the plant’s 32-year history and the seventh time the plant has exceeded 400,000 units.

Since 1992, the BMW Group has invested nearly $16 billion in its South Carolina operations. BMW Manufacturing is the largest BMW Group plant in the world, assembling more than 1,500 vehicles each day. The plant is an important part of BMW’s global production network and plays a critical role in meeting the high demand for BMW Sports Activity Vehicles and Coupes in the U.S. and around the world. About 50 percent of its vehicles are shipped to nearly 120 global markets, making the BMW Group the largest automotive exporter by value in the United States for more than a decade. In 2025, more than 52 percent of BMW vehicles sold in the United States came from Plant Spartanburg. The model portfolio includes five top-selling BMW X models, three Motorsport X models, and two plug-in hybrid electric vehicle X models. The factory has an annual production capacity of up to 450,000 vehicles and has more than 12,000 jobs onsite. 

# # #

BMW Manufacturing Co., LLC

BMW Manufacturing Co., LLC is a subsidiary of BMW AG in Munich, Germany, and assembles the BMW X3, X5, X5 M, X7, and XM Sports Activity Vehicles and the BMW X6 and X6 M Sports Activity Coupes.  In addition to the South Carolina manufacturing facility, BMW Group North American subsidiaries include sales, marketing, and financial services operations in the United States, Canada and Latin America; a manufacturing plant in San Luis Potosi, Mexico; and a design firm and technology office in California. For more information on BMW Manufacturing, visit www.bmwusfactory.com.

BMW Group in the United States.
BMW Group began operations in the U.S. over 50 years ago. In addition to the sales, marketing, and distribution of BMW, MINI, Rolls-Royce, and BMW Motorrad vehicles, BMW Group’s business in the U.S. spans 30 locations in 12 states including BMW Group Financial Services, BMW Manufacturing, Designworks, BMW Technology Office USA, and BMW i Ventures. The company’s U.S. plant in South Carolina is the largest single BMW production facility in the world and the global center of competence for BMW Sports Activity Vehicles. The BMW Group sales organization is represented by a nationwide network of 355 BMW retailers, 147 BMW motorcycle retailers, 105 MINI passenger car dealers, and 37 Rolls-Royce Motor Car dealers. Taken together, BMW Group’s business activities in the U.S. provide and support over 120,000 jobs and contribute more than $43.3 billion to the U.S. economy annually.

For more information about BMW Group’s business and products in the U.S., please visit: PressClub USA.

# # #

• The BMW ALPINA XB7 Was Completed in April.
• The Seven Millionth BMW Will Become Part of the BMW Historic Collection.

Spartanburg, SC – April 30, 2025… BMW Manufacturing is celebrating a historic milestone this month as the seven millionth BMW rolled off the assembly line in Spartanburg, SC. To commemorate this special event, associates assembled a truly exceptional vehicle – a BMW ALPINA XB7 painted ALPINA Green Metallic and powered by a 4.4-liter BMW ALPINA Bi-Turbo V8, 32-valve engine, producing an impressive 631 horsepower. Due to its significance, this vehicle will remain at the factory and become part of the BMW historic collection.

"This beautiful BMW ALPINA XB7 is a testament to the great products we have, the quality of our supplier network, and the unwavering commitment and dedication of our valued associates,” said Dr. Robert Engelhorn, president and CEO of BMW Manufacturing. “For over 30 years, BMW has proudly invested in South Carolina and its people, creating a remarkable legacy. We are excited about our future as we prepare to assemble fully electric vehicles at this plant."

Associates finished assembling the seven millionth BMW at the end of March. However, special “white glove” modifications by Plant Spartanburg’s ALPINA team were made during the next week. This included a specially designed ALPINA front apron, rear diffuser, and rear spoiler; floormats with the ALPINA emblem; and the installation of an ALPINA commemorative badge.

Other special features of the BMW ALPINA XB7 include 23-inch ALPINA CLASSIC CS16 wheels, Tartufo Full Merino Leather upholstery, ALPINA Walnut Nature Black trim, Panoramic Sky Lounge LED Roof, and second-row captain’s chairs. The leather steering wheel has blue and green stitching with an ALPINA badge in the center.

Associates at the South Carolina plant assembled nearly 400,000 BMWs in 2024 with nearly 225,000 of these vehicles exported to 120 countries around the world. Below are the milestone dates for BMW Manufacturing’s “millionth” vehicles:

• 1 Millionth BMW – February 28, 2006 – Z4 M Roadster
• 2 Millionth BMW – January 12, 2012 – BMW X3 xDrive35i
• 3 Millionth BMW – March 24, 2015 – BMW X5 M
• 4 Millionth BMW – September 8, 2017 – BMW X3 xDrive M40i
• 5 Millionth BMW – June 4, 2020 – BMW X5 M Competition
• 6 Millionth BMW – September 2, 2022 – BMW X6 M
• 7 Millionth BMW – April 30, 2025 – BMW ALPINA XB7

The BMW Group is investing more than $1.7 billion in its U.S. operations, including $1 billion to prepare Plant Spartanburg for the assembly of electric vehicles and $700 million for Plant Woodruff, a new high-voltage battery assembly plant in nearby Woodruff, S.C. By 2030, Plant Spartanburg will assemble at least six fully electric vehicles along with internal combustion engine and plug-in hybrid electric vehicles on the same site.

Since 1992, the BMW Group has invested more than $14.8 billion in its South Carolina operations. BMW Manufacturing is the largest BMW Group plant in the world, assembling more than 1,500 vehicles each day. The plant is an important part of BMW’s global production network and plays a critical role in meeting the high demand for BMW Sports Activity Vehicles and Coupes in the U.S. and around the world. Nearly 57 percent of its vehicles are shipped to 120 global markets, making BMW the largest automotive exporter by value in the United States for more than a decade. In 2024, nearly 50 percent of BMW vehicles sold in the U.S. came from Plant Spartanburg.  The model portfolio includes six top-selling BMW X models, four Motorsport X models, and two plug-in hybrid electric vehicle X models. The factory has an annual production capacity of up to 450,000 vehicles and employs more than 11,000 people. 

BMW Group in the United States.

BMW of North America, LLC was established 50 years ago to support the sales, marketing and distribution of BMW automobiles in the U.S. BMW Motorrad was brought into the fold in 1980. In 1993 BMW Group Financial Services NA, LLC was founded, and one year later BMW Manufacturing Co., LLC began assembling vehicles in South Carolina. In 2002 and 2003, BMW Group established MINI USA, and Rolls-Royce Motor Cars NA, LLC relaunching two iconic brands and rounding out its product portfolio.

Today, the BMW Group has a nationwide corporate footprint in the U.S. which consists of nearly 30 locations in 12 different states. Beyond the National Sales Company and Financial Services headquarters in Woodcliff Lake, NJ, its manufacturing plant in Spartanburg, South Carolina, and numerous other operational facilities, BMW Group in the U.S. also includes Designworks, a strategic design consultancy in Santa Monica, CA, BMW Group Technology Office USA, a technology research and development center in Silicon Valley, and BMW i Ventures, a venture capital fund, also in Silicon Valley.

BMW Group Plant Spartanburg is the largest single BMW production facility in the world, and the global center of competence for BMW Sports Activity Vehicles including the X3, X4, X5, X6, X7, and XM. The plant assembles more than 1,500 vehicles each day, and up to 450,000 annually. Since 1994, Plant Spartanburg has assembled nearly 7 million BMW vehicles in the U.S.

The BMW Group sales organization in the U.S. is represented through a network of 350 BMW retailers, 144 BMW motorcycle retailers, 105 MINI passenger car dealers, and 38 Rolls-Royce Motor Car dealers. The company’s activities provide and support over 120,000 jobs across the U.S. and contribute more than 43.3 billion to the U.S. economy annually.

# # #

Journalist note: Information about BMW Group and its products in the USA is available to journalists on-line at www.bmwusanews.com www.miniusanews.com and www.press.bmwna.com

Munich/Spartanburg, USA. The BMW Group is exploring the use of humanoid robots in production for the first time. During a trial run lasting several weeks at BMW Group Plant Spartanburg, the latest humanoid robot Figure 02 from California company Figure successfully inserted sheet metal parts into specific fixtures, which were then assembled as part of the chassis. The robot must be particularly dexterous to complete this production step.

At the same time, using a robot can save employees from having to perform ergonomically awkward and tiring tasks. Together with Figure, the BMW Group is currently testing and evaluating how humanoid robots can be used safely in automobile production. This video shows the trial run in the body shop at BMW Group Plant Spartanburg: https://b.mw/Figure_02

“The developments in the field of robotics are very promising. With an early test operation, we are now determining possible applications for humanoid robots in production. We want to accompany this technology from development to industrialization,” says Milan Nedeljković, Member of the Board of Management for Production at BMW AG.

With the BMW iFACTORY, the vision for the production of the future, the BMW Group is always on the lookout for new technologies. Efficiency, digitalisation and sustainability are central to this vision to realisation. During the trial run, the BMW Group gained valuable knowledge of what requirements must be met in order to be able to integrate so-called multi-purpose robots in an existing production system. This includes how humanoid robots communicate with the system under real conditions. After the first use in automobile production, the experts at the BMW Group and Figure are collaborating to prepare Figure for future applications in production and continuing to develop the robots, based on the findings.

Figure 02 embodies the latest technological advances in robotics 

“We are excited to unveil Figure 02, our second-generation humanoid robot, which recently completed successful testing at the BMW Group Plant Spartanburg. Figure 02 has significant technical advancements, which enable the robot to perform a wide range of complex tasks fully autonomously,” says Brett Adcock, Founder and CEO of Figure.

According to the California company, Figure 02 is the world’s most advanced humanoid robot currently available on the market. The combination of two-legged mobility and advanced dexterity means that the Figure 02 is ideally suited for use in areas with physically demanding, unsafe, or repetitive processes, thereby improving ergonomics and safety for associates. Figure 02 boasts three times the processing power of its predecessor, improved voice communication, better cameras, microphones, and sensors, a high-performance battery, and fourth-generation human-scale hands with 16 degrees of freedom per hand and human-equivalent strength.

The robot is capable of fully autonomous execution of human-like and two-handed tasks requiring varied and dynamic manipulation, complex grasping, and coordination of both hands in unison. It is able place various complex parts with accuracy measured in millimetres and can walk dynamically leveraging efficienties of the robot’s design.

Currently, there are no Figure AI robots at BMW Group Plant Spartanburg, and there is no definite timetable established for bringing Figure robots to the plant. BMW Group will continue to work with Figure for data capturing and training capabilities for the Figure02 robots.

Munich. The BMW Group is accelerating its ramp-up of e-mobility and increasingly relying on regional supply chains, in line with the principle “local for local”. The company aims to source components like battery cells close to vehicle production and gradually localise the supply chain for primary materials.

New partner to supply primary material for battery cell production 

Belgian company Umicore has now been recruited as a further partner for establishing a local supply chain in North America. Umicore will supply our battery cell supplier AESC with cathode active battery materials from a new plant in Ontario, Canada. This is an important step in strengthening the BMW Group's regional supply chains and securing the ramp-up of e-mobility.

In accordance with the “local for local” principle, our partner AESC is currently building a battery cell factory in Florence, South Carolina. With an initial capacity of 30 GWh/a, the facility will produce the innovative cylindrical lithium-ion battery cells specifically developed for the sixth generation of BMW eDrive technology. Electricity for production of the battery cells and cathode raw material will come exclusively from renewable sources.

“The BMW Group pursues a globally balanced procurement strategy in the three main geographical regions of the world. Our battery cell supplier in the US will source key primary materials from Canada going forward. We are pleased that Canada is playing a strong role in establishing a robust and efficient battery cell supply chain for the BMW Group in North America,” said Joachim Post, member of the Board of Management of BMW AG responsible for Purchasing and Supplier Network.

Further BMW Group investment in South Carolina

Oliver Zipse, Chairman of the Board of Management of BMW AG, already announced an extensive investment of 1.7 billion US dollars in expansion of the US production site back in October 2022. This includes 700 million US dollars to build the BMW Group’s new assembly centre in Woodruff, which will provide high-voltage batteries for the fully-electric BMW X models in the future. In the initial phase, the roughly 93,000 sq. m. facility will produce sixth-generation battery modules. The assembly centre will also create about 300 new jobs.

Sixth-generation battery cell technology for better performance and sustainability 

The new sixth-generation battery format will increase energy density by more than 20 percent and improve charging speed and range by up to 30 percent. At the same time, CO₂ emissions from cell production will be reduced by up to 60 percent: on the one hand, by cell suppliers relying on energy from renewable resources; on the other, by using a percentage of secondary material for the raw materials lithium, cobalt and nickel.