Munich. BMW Group Plant Munich is gearing up to launch the NEUE KLASSE in summer 2026. During ongoing series operation, three new production halls are currently being built for the body shop, assembly and associated production logistics. “For the production start of the NEUE KLASSE, we will have a state-of-the-art plant in Munich that is characterised by flexibility, innovation and, above all, efficiency,” says Plant Director Peter Weber.

Starting in 2027, the plant in Munich will exclusively produce fully-electric vehicles, further enhancing efficiency boost. Forward planning, close cooperation with development teams and suppliers, and the integration of modern production technology within new structures will all play a key role. “With the NEUE KLASSE, we will significantly reduce manufacturing costs at the Munich Plant,” says Weber. In addition to optimised production processes and targeted automation, the NEUE KLASSE’s new vehicle architecture will also leverage further efficiencies. Focusing on a single drive train variant reduces production steps and the number of parts – for example, for wiring harnesses, which previously varied according to engine type and can be complex to install.

Unusual process: Pre-series production at pilot plant
The timeline for the ramp-up in Munich is carefully synchronised – in part due to the plant’s refurbishment. The first pre-series vehicles will be built at the pilot plant of the BMW Group Research and Innovation Centre (FIZ), with support from Plant Munich’s production team, before the end of the year. “Alongside the pilot plant at the FIZ, we are also using virtual simulations to ensure a smooth ramp-up,” says Weber, describing the unusual situation in the decisive year ahead of the launch. He adds that Plant Munich’s experienced launch team is also working closely with colleagues at the new plant in Debrecen, Hungary, where the first NEUE KLASSE model will enter production late this year.

International production network: Cooperation, flexibility and innovative processes
BMW Group plants are capable of producing different model variants and drive train types on a single line. Since the ramp-up of electromobility is not linear and will progress at varying speeds, the company has relied on “flex-plants”, which can manufacture vehicles with both internal combustion engines and electric drive trains. “In this way, we can ensure our delivery capabilities in different market situations and maintain good capacity utilisation at our locations,” explains Milan Nedeljković, member of the Board of Management responsible for Production.

By the end of the decade, the BMW Group expects a significant increase in the market shares of fully-electric vehicles. For this reason, the plants in Debrecen and, later, Munich will be the first facilities dedicated exclusively to fully-electric vehicles, enhancing electrification capacities throughout the network.

The German plants lead the way on e-mobility in the BMW Group’s production network: Alongside traditional drive technologies, each of them builds at least one fully-electric model for the global market. Even in a volatile environment, the BMW Group continues to grow its domestic locations, manufacturing over a million vehicles there last year – accounting for a quarter of Germany's total automotive production.

At the same time, the company’s production also depends on a balanced global distribution of value creation. “The strategic and flexible structure of our production network strengthens our resilience and makes us more competitive,” adds Nedeljković.

Focus on employees: Developing skills for e-mobility
The shift towards electrified vehicles also brings changes to employee roles and required skills. With the flexible ramp-up of e-mobility at BMW Group plants, employees can gradually be prepared for new job content.

“Despite technical and structural innovations, our focus is always on people. We take pride in our employees’ expertise and experience, and their dedication to continuous improvement. It is thanks to their commitment that we are able to consistently deliver premium-quality vehicles,” emphasises Weber. Additional expertise will be developed and retained at the company through extensive further training and workforce flexibility. Last year alone, nearly 25,000 employees completed e-mobility training. Plant Munich is currently holding its third industrial electrician qualification course, conducted in cooperation with the Chamber of Industry and Commerce (IHK).

In recent years, around 5,500 jobs have been created across the BMW Group production network for the current and upcoming generation of e-drives. More than three quarters of these positions were filled through internal reorganisation. 

For further information about flexibility in the BMW Group production network please also note the background document in the download section.

Steyr. Just ten months after the start of system installation, the first electric engine was now shipped from BMW Group Plant Steyr to Debrecen, Hungary. At BMW Group Plant Debrecen, the e-engine will be used in Neue Klasse test vehicles.

“Our plant in Steyr has been delivering the first sixth-generation electric engines to the development department in Munich since September. We also recently began sending our e-engines directly to BMW Group Plant Debrecen, where they are being installed in test vehicles,” explains Klaus von Moltke, SVP Engine Production at BMW AG and Managing Director of BMW Group Plant Steyr.

Plant Steyr already launched production of the first next-generation electric motors three months ago. Helmut Hochsteiner, VP of Electric Engine Production at BMW Group Plant Steyr, adds: “Over the coming months, we will continue to validate and optimise the complex production process for the new electric motors,” The supply of Plant Debrecen with electric engines from Steyr marks the next important milestone towards the start of series production – both Neue Klasse and its electric motors from Austria.

Further information on the production of test vehicles at BMW Group Plant Debrecen can be found in the BMW Group PressClub.

This is BMW Group Plant Steyr

The BMW Group's largest engine plant worldwide is located in Steyr in Upper Austria, where 4,700 employees produce over one million petrol and diesel engines each year. Steyr is also home to a major development centre for the research and development of new drive trains. In June 2022, the company announced that it would begin production of e-drives in 2025. BMW Motoren GmbH in Steyr is currently one of Austria's top industrial companies in terms of revenues and exports.

Munich, Dingolfing, Leipzig. The BMW Group is systematically advancing the digitalisation and automation of its production processes within the BMW iFACTORY framework. Since 2022, the company has been testing Automated Driving In-Plant (AFW) for new vehicles at its largest European plant in Dingolfing. Following successful CE certification, the pilot project is now transitioning into series operation.
In addition to Dingolfing, Leipzig is also currently being enabled to implement the AFW project in series operation. Other facilities in the BMW Group production network are set to follow in stages.

“Automated Driving In-Plant optimises our production process and delivers significant efficiency gains for our logistics,” explains Milan Nedeljković, member of the Board of Management of BMW AG responsible for Production. “That is why we will be swiftly rolling out this technology throughout our production network.”

In addition to the BMW 5 Series and 7 Series in Dingolfing, this technology is now also being used for the MINI Countryman and other BMW models in Leipzig. In Dingolfing the new vehicles drive fully autonomously – without a driver – along a route of more than one kilometre, from the two assembly halls, through the “short test course”, to the plant’s finishing area. This is made possible by sensors installed along the route – creating the largest LIDAR infrastructure in Europe – and relying on an externally generated environment model and an external movement planner. Regardless of the vehicle's equipment options, this system controls its automated movements, using state-of-the-art cloud architecture. Parts of the technology were provided by the young Swiss company Embotech AG, which the BMW Group already cooperated with in the early stages through its venture client unit, the BMW START-UP Garage.

Plant Leipzig plans to introduce automated driving for around 90 percent of the BMW and MINI models built there, with Plants Regensburg and Oxford set to follow in 2025. The new site in Debrecen, Hungary, will also implement this technology from the official launch of series production.

Going forward, the BMW Group plans to expand its use of Automated Driving In-Plant to other areas of production, such as for driving through the testing zone and in outdoor distribution areas. Production and development experts are also working closely together to refine the technology in-house. Another key factor in expanding the technology is the increasing use of on-board technology, which will support the external sensors in the long term.

“Over the next ten years, we will log several million test kilometres with Automated Driving In-Plant in our production network alone,” says Nedeljković. “In this way, the BMW Group is once again setting a new benchmark for automation and digitalisation of its production processes – while paving the way for future applications in the field of autonomous driving.”

Today MINI Plant Oxford celebrates the start of production of the MINI Cooper Convertible for the first time since 2015. The model joins the MINI Cooper 3-Door and MINI Cooper 5-Door, making MINI Plant Oxford the home of the MINI Cooper family.

Announced last month, the fourth generation MINI Cooper Convertible includes a completely new interior and exterior design, as well as a state-of-the-art digital experience.

“We are thrilled about the start of production of the MINI Convertible, which is now being produced again at the Oxford plant, the home of MINI. Unique in its class, the MINI Convertible offers unparalleled, brand-typical driving fun, combined with boundless freedom and great emotions: The iconic design combined with modern technology and connectivity makes this vehicle an unmatched open-air experience for our customers," says Stefan Richmann, Head of MINI.

Three UK BMW Group manufacturing sites contribute to the MINI Cooper Convertible. BMW Group Plant Swindon produces the body pressings and sub-assemblies while the latest four-cylinder petrol engines are built at BMW Group Plant Hams Hall in North Warwickshire. Finally, these parts come together at MINI Plant Oxford where body shell production, paint and final assembly take place.

Following the relaunch of the MINI brand in 2001, the first MINI Convertible was unveiled in 2004 and has remained an icon of the MINI family ever since.

With 160,000 vehicles built at MINI Plant Oxford from 2004 to 2008, the first-generation MINI Convertible was known for its retro styling and iconic chrome roll-over arches behind the rear seats. The second generation, unveiled in 2009 with 165,000 built at MINI Plant Oxford until 2015, kept the iconic drop-down hinged boot but gained the evolved styling of the Cooper from that era.

Production of the model was briefly moved to VDL Nedcar for the third generation, making room for the MINI Clubman at MINI Plant Oxford. Over 150,000 Convertible models were produced at Nedcar until production stopped in 2023, before production returned to MINI Plant Oxford.

MINI Plant Oxford celebrated its 110^th anniversary in 2023, the same year the Plant produced over 20% of all UK manufactured cars. As one of the oldest automotive plants in the world, MINI Plant Oxford has been in continuous production since 1913.

In case of queries, please contact:

Corporate Communications

Julian Kisch, Press Spokesperson, Product Communications MINI
Phone: +49-151-601-38072
E-mail: julian.kisch@mini.com

Micaela Sandstede, Head of Communications MINI
Phone: +49-176-601-61611
E-mail: micaela.sandstede@bmw.de

Dingolfing. Today, four months after the start of production for the BMW M5 Sedan, series production of the new BMW M5 Touring got underway at BMW Group Plant Dingolfing (consumption weighted, combined: 2.0 l/100 km and 30.7 kWh/100 km; CO2 emissions weighted, combined: 46 g/km; fuel consumption with discharged battery: 10.9 l/100 km (WLTP); CO2 classes: weighted, combined B; with discharged battery G). The new model combines exceptional driving dynamics with versatile space for everyday life, leisure and travel.

It is the third current BMW M vehicle to feature an M HYBRID drive train in which a high-rpm V8 power train is complemented by an e-drive with extremely responsive power development. Together, the two engines deliver a peak performance of 535 kW/727 hp and a maximum torque of 1,000 Nm.

“With the BMW M5 Touring, the new BMW 5 Series family ‘made in Dingolfing’ is complete,” says Plant Director Christoph Schröder. “We can now offer customers of our core model series worldwide a unique variety of drive technologies and body variants.”

With the addition of the new model, the location also continues to expand its production of BMW M high-performance cars. Alongside the BMW M4 Coupé and Convertible, the BMW M8 Coupé, Convertible and Gran Coupé and the BMW M5 Sedan, the new BMW M5 Touring is the seventh
M derivative to come off the Dingolfing production line. BMW M models account for around six percent of Dingolfing's total production.

Munich. The Neue Klasse will usher in a new era of fully electric driving at the BMW Group – the success of which will depend heavily on the production of powerful high-voltage batteries. That’s why the BMW Group is expanding its production network for the next generation of high-voltage batteries significantly. “We are setting up five facilities on three continents to produce our sixth-generation high-voltage batteries,” explained Milan Nedeljković, Board Member for Production at BMW AG. Across the globe, the principle of “local for local” will apply: "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.

Battery and vehicle production closely connected

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 located as closely as possible to vehicle plants, in keeping with the principle of “local for local”. State-of-the-art 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 will be able to continue even when unexpected political or economic events occur. In addition, short distances between battery and vehicle plants will reduce the carbon footprint of car production. The BMW Group is also upgrading its existing sites and therefore securing and creating jobs.

Neue Klasse to launch first at Plant Debrecen in 2025

The first Neue Klasse vehicles will be produced at the BMW Group’s new plant in Debrecen, starting in 2025. High-voltage battery and vehicle manufacturing will launch in parallel. With the training centre in Debrecen open since autumn 2023 and the communications centre in use since February 2024, a large number of employees are already at work in their offices at the site. The production team, meanwhile, are preparing for their new jobs at various locations across the BMW Group production network. This will ensure a smooth start to pre-series production and a successful series launch in the second half of 2025. Currently, the final buildings are being completed. They will be handed over to the technologies by the end of the year.

High-voltage batteries from Lower Bavaria

The BMW Group is also going to manufacture high-voltage batteries for Neue Klasse models in Germany – specifically in Irlbach-Straßkirchen, in Lower Bavaria. The new facility will supply sixth-generation high-voltage batteries to German car plants. The BMW Group was granted permission to build the new high-voltage battery assembly plant in April 2024 and erected the first of pillar for the production hall in late June 2024. The production building is scheduled to be enclosed with facade and roof by the end of the year. The citizens of Straßkirchen had previously voted in favour of the BMW Group coming to their area, with a clear majority in the referendum of September 2023.

China to produce the Neue Klasse from 2026

From 2026 Neue Klasse vehicles will also be made by BMW Brilliance Automotive (BBA) in Shenyang, China. Here, too, the sixth-generation high-voltage batteries required for the cars will be manufactured locally. The production hall was completed in November 2023 after a construction time of only 21 months. The installation of plant and machinery has been underway since March 2024. Preparing for the launch of the Neue Klasse, the BMW Group has also set up its largest R&D network outside Germany, with facilities in Beijing, Shanghai, Shenyang and Nanjing.

Neue Klasse in Mexico from 2027

At San Luis Potosí in Mexico, additional production capacity is being established for series production of the Neue Klasse to start in 2027. Construction of the new high-voltage battery assembly plant started in May 2024 and will comprise more than 80,000 square metres of production space when completed. But the integration of battery assembly is not all that’s changing at Plant San Luis Potosí: the bodyshop is set to grow to more than 90,000 square metres in total, while vehicle assembly and logistics spaces will expand by nearly 10,000 square metres. The BMW Group is the first premium OEM to manufacture fully electric cars and high-voltage batteries in Mexico – and a pioneer in the industry. Additionally, the company plans to expand the photovoltaic systems within the plant and thus double the power generated from photovoltaics. This is intended to generate more than 20 percent of the current electricity demand directly on the plant premises in the future.

BMW Group Plant Woodruff: High-voltage batteries for Spartanburg

Electromobility is also advancing in South Carolina. BMW Group Plant Woodruff will cover an area of about 93 hectares and consist of a technology building, ancillary structures, an energy centre, a staff restaurant, a fire department and a Talent Campus. It will create more than 300 new jobs with the BMW Group. When construction reaches completion in 2026, Woodruff will assemble high-voltage batteries for fully electric cars made in nearby Plant Spartanburg. The ground-breaking ceremony for the first building in Woodruff – the training centre – was in June 2023.

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.

Munich. With more than 30 years of experience, the BMW Group is a pioneer in the field of additive manufacturing, better known as 3D printing. 3D printers have been used from as early as 1991 to produce individual vehicle parts and components, initially for concept cars, prototypes and race cars, then later for production models. The BMW Group now also manufactures many work aids and tools for its own production system in various 3D printing processes. From tailor-made orthoses for employees, and teaching and production aids, to large, weight-optimised robot grippers, used for such things as CFRP roofs and entire floor assemblies. At the “Additive Manufacturing Campus” in Oberschleißheim, the BMW Group’s central hub for production, research and training in 3D printing, more than 300,000 parts were “printed” in 2023. Furthermore, over 100,000 printed parts were produced per year across all the plants that form the global production network, from Spartanburg and the German plants to sites in Asia.

“The increasing use of additive manufacturing in the BMW Group production system has many benefits. For example, we are able to quickly, economically, and flexibly produce our own production aids and handling robots, which we can individually adapt to specific requirements at any time, as well as being able to optimise their weight. Less weight allows higher speeds on the production line, shorter cycle times and reduced costs. Plus, smaller robots can be used in the medium term, which also cuts CO₂ emissions and costs,” says Jens Ertel, Head of BMW Additive Manufacturing.

“As well as the direct additive manufacturing procedure, the BMW Group has also been using sand-based 3D printing to create moulds for many years at its site in Landshut. This technology is typically used to manufacture prototype casts, as well as for the large-scale production of components for high-performance motors. Another very attractive field of application is now that of large production aids,” says Klaus Sammer, Head of Product and Process Planning for Light Metal Casting.

Printed moulds for the production of aluminium cylinder heads in large-scale production

Additive manufacturing processes have been used on a daily basis for a long time at BMW Group Plant Landshut. For many years, these have included moulds for the manufacturing of aluminium cylinder heads, which are printed three-dimensionally using the sand casting process. Here, sand is repeatedly applied in thin layers and stuck together using binders. This makes it possible to create moulds for the manufacturing of very complex structures, which are then filled with liquefied aluminium.

Using 3D printing to manufacture large robot grippers for CFRP roofs

For a number of years, the BMW Group’s Lightweight Construction and Technology Centre in Landshut has been using a particularly large gripper element, which was made using the 3D printing process. Weighing around 120 kilograms, the gripper for a robot can be manufactured in just 22 hours and is then used on a press in the production of all CFRP roofs for BMW M GmbH models. The press is first loaded with the CFRP raw material. The gripper is simply rotated 180 degrees to remove the finished roofs. Compared to conventional grippers, the version manufactured using 3D printing was roughly 20 percent lighter, which in turn extend the operating life of the robots and also reduced wear and tear on the system, as well as cutting maintenance intervals. The combined use for two steps also reduced the cycle time. A unique feature of the robot gripper is the ideal combination of two different 3D printing processes. While the vacuum grippers and the clamps for the needle gripper to lift the CFRP raw material are made using selective laser sintering (SLS), the large roof shell and bearing structure are manufactured using large scale printing (LSP). LSP can be used to produce large components economically and sustainably. The process uses injection moulding granules and recycled plastics, while CFRP residual material can also be used and recycled. Compared to the use of primary raw materials, CO₂ emissions when manufacturing the gripper are roughly 60 percent lower.

Further weight savings, courtesy of new generation of bionic grippers

In the summer of 2023, a new, even lighter generation of gripper was introduced. To achieve this, the previous gripper concept was analysed and optimised topologically – the birth of the bionic robot gripper. This combines the roof shell from the LSP printer with SLS vacuums and a bionically optimised bearing structure. For this, a mould with printed cores is used in the sand casting. This mould is then cast with the intricate aluminium structure. The new gripper is a further 25 percent lighter than its predecessor, meaning the entire process of manufacturing a CFRP roof of the BMW M3 can be performed with just one robot, rather than three as was previously the case. Nowadays, double grippers manufactured individually within the BMW Group, courtesy of 3D printing, are used for all CFRP roofs at BMW Group Plant Landshut.

New 3D-printed gripper also used in chassis construction in operation

The BMW Group also employs grippers produced using the 3D printing process in chassis construction – for example, grippers printed with the LSP process for dealing with doors at BMW Group Plant Regensburg. “With an optimised bearing structure produced using 3D printing, we were able to increase the rigidity of the gripper when handling door elements at the plant in Regensburg, while at the same time reducing weight. In subsequent projects, it is then possible to use robots with a low bearing capacity, which helps to cut costs,” says Florian Riebel, Head of Door and Flap Production in Regensburg.

However, the company is now taking it one step further at BMW Group Plant Munich. As of recently, the first examples of a bionic robot gripper have been used at the parent plant. This gripper can hold and move the entire floor assembly of a BMW i4. For the floor assembly gripper, 3D printing is used to create a sand casting mould, which is filled with liquid aluminium. The bearer is optimised in terms of weight and maximum load capacity, and weighs with all additional add-on elements a mere 110 kilograms. That makes it roughly 30 percent lighter than the previous, conventional model. Manufacturing using sand casting and aluminium makes it possible to represent intricate load-optimised structures. This results in maximum weight reduction and thus makes it possible in the medium term to use smaller and lighter heavy-duty lifting robots, which require less energy and thus reduce CO₂ emissions. Markus Lehmann, Head of Plant Engineering and Robotics at BMW Group Plant Munich: “At the Munich plant, we are continuously expanding the use of production aids created through additive manufacturing. When it comes to the field of gripper and handling systems, we use 3D printing to equip our established grippers with individual, printed attachments and are already replacing complete gripper systems with highly-integrated and weight-optimised bearing structures. When handling the full BMW i4 floor assembly, this allowed us to reduce the weight of the complete gripper by 30 percent – 50 kg – and thus to extend the service life of our facilities.”

Use of innovative software solutions in additive manufacturing

Intricate and bionic structures are designed and calculated using special generic software tools, such as Synera. BMW iVentures had strategically invested in this software, previously known as Elise. Synera allows fast and efficient optimisation and is now used in many development areas within the BMW Group. It is particularly worth using the software in 3D printing, as topologically optimised, bionic structures can virtually be printed one to one, thanks to the high degree of flexibility of the 3D printing process. This makes it possible to exploit the full potential for lightweight construction. The BMW Group’s Additive Manufacturing Campus is home to a team of design and construction specialists, who compare a diverse range of software solutions and use them to design components. The knowledge is then passed on throughout the company via the Additive Manufacturing Campus. In the case of gripper design, special workflows have been developed and implemented, which allow the calculation and construction of the bearing structure to be largely automated, and thus fast and efficient.

San Luis Potosí. BMW Group Plant San Luis Potosí is gearing up for production of the Neue Klasse: Construction of a local high-voltage battery assembly has now begun, along with expansion projects for the body shop, assembly and logistics areas. A total of 800 million euros will be invested in expanding the Mexican production site.

The Neue Klasse will also be produced in Mexico from 2027 onwards. The Sports Activity Vehicle model will be launched at the new BMW Group Plant Debrecen in Hungary as the initial derivative of the Neue Klasse in late 2025, while the Sedan will ramp up in Munich in 2026. Just one year later, additional production capacity will be available in Mexico – initially, for the Sports Activity Vehicle. The future high-voltage battery assembly at Plant San Luis Potosí, covering an area of more than 80,000 square metres, is key to integrating the Neue Klasse at the production site.

“The battery assembly in San Luis Potosí will be part of our global production network. For our new sixth-generation e-drive alone, we are building five locations on three continents,” explained Milan Nedeljković, member of the Board of Management of BMW AG responsible for Production, at the start of construction in Mexico. The BMW Group is committed to the “local for local” principle worldwide. “Locating battery factories close to vehicle manufacturing makes production more resilient.”

Close links between battery factory and vehicle production

In line with its “local for local” principle, the BMW Group locates its high-voltage battery assembly facilities worldwide as close as possible to its vehicle plants. In addition to the location in San Luis Potosí, assembly sites for sixth-generation high-voltage batteries are also being built in Debrecen (Hungary), Shenyang (China), Woodruff, near Spartanburg (USA) and Irlbach-Straßkirchen (Lower Bavaria). This approach safeguards production, even in the event of unforeseen political and economic developments. Existing locations are also being strengthened, securing jobs. The short distances involved reduce the carbon footprint of vehicle production.

The BMW Group will use its newly developed round cells for the first time in the Neue Klasse. This leap in technology will boost the energy density of cells by 20 percent and improve charging speed by up to 30 percent. Range will be extended by 30 percent. 

Further development of Plant San Luis Potosí

As well as integrating battery assembly, other changes are being made at Plant San Luis Potosí: Just under 20,000 square metres will be added to the body shop, resulting in a total area of over 90,000 square metres. Assembly and logistics areas are also being expanded by almost 10,000 square metres.

“With this further development of our site, we are also gearing up in Mexico for the launch of the next BMW model generation. As the first premium OEM producing fully-electric vehicles and high-voltage batteries in Mexico, we are at the forefront of our industry and, at the same time, continuing to reduce our environmental footprint,” said Harald Gottsche, president and CEO of BMW Group Plant San Luis Potosí.

Photovoltaic output to double

When it comes to efficient energy supplies, the BMW Group uses site-specific solutions at its locations around the world. “In Mexico, we are planning to expand the photovoltaic systems within the plant, to double the output from the solar panels,” said Nicole Haft-Zboril, Head of Real Estate Management at the BMW Group. “The plan is to generate more than 20 percent of the electricity we need at the moment – directly on the factory premises.” The wastewater treatment plant has also been expanded, with an investment of 3.3 million euros significantly increasing the reuse of treated wastewater.

Extensive skills development programme

BMW Group Plant San Luis Potosí is also stepping up its commitment to skills development, aimed at ensuring employees are highly qualified and prepared for the challenges of the future. Training will include topics such as safety awareness around production of high-voltage systems and the use of robotics in manufacturing processes.

The BMW Group plant in San Luis Potosí started production in 2019. Around 3,700 employees currently produce the BMW 3 Series Sedan as well as the BMW 2 Series Coupé and the BMW M2 models for the global market.

Munich. At the Additive Manufacturing Campus in Oberschleißheim, the BMW Group has a “live wire” to an innovative, additive production process for metallic vehicle components and tools. In wire arc additive manufacturing (WAAM), a wire made of aluminium or similar is melted using an arc. Then a software-controlled robot places a large number of welding seams on top of each other with precision, until the complete component is finished. Because the pressure means that layer by layer there is no need to pay attention to demouldability, hollow structures with an optimum ratio between rigidity and weight are possible. This means that the components can be lighter and more rigid than comparable die-cast parts currently manufactured in series production. They can also be produced more sustainably thanks to lower energy requirements and less material waste. In the future, the plan is to use components manufactured using the WAAM process in BMW Group production vehicles.

The WAAM process is particularly suitable for large components

The large width and height of a single welding seam means that components can be produced extremely quickly using WAAM. In contrast to laser beam melting, which is already used in prototype and small series production at the BMW Group, WAAM is particularly suitable for larger components. The typical wall thicknesses are well suited to components in the body, drive, and chassis areas. However, tools and devices can also be manufactured using this high-tech process, which is also used in the aviation industry.

Development at the Additive Manufacturing Campus

The BMW Group is trialling this process at the Additive Manufacturing Campus in Oberschleißheim, where they have pooled production, research, and training in this area under one roof. With more than 30 years’ experience, the company is a pioneer in the area of additive manufacturing, commonly known as 3D printing. BMW Group employees have been focussing on the WAAM process, also known as build-up welding, since 2015. A WAAM cell for the production of test components has been in use there since 2021. One of these example applications is a suspension strut support, which, in extensive testing on the test bench, is being compared with the series production component made from aluminium pressure die-casting. “In this early stage it is already clear that the WAAM process can result in lower emissions in the production process. The lower weight of the components, their advantageous material usage ratio, and the option to use renewable energy means that the components can be produced more efficiently,” said Jens Ertel, Head of BMW Additive Manufacturing. The next stage of development on the road to series production is testing components in the vehicle, which will start in the foreseeable future.

The wider welding seams in the WAAM process mean that the surfaces of the components are not smooth, but slightly rippled and must be finished in critical areas. However, BMW Group engineers were able to demonstrate that WAAM components can be used for high loads, including cyclical loads, even without post-treatment of the surface. Optimised process parameters are crucial for ensuring durability directly from production, so the combination of welding process and robotic path planning must be coordinated optimally.

Configuration with generative design and algorithms

To make optimum use of the components produced in the WAAM process, the combination of the manufacturing process and a general new component design is paramount. To this end, the BMW Group continues to accelerate the use of generative design. Here, the computer uses algorithms to design optimised components based on the specific requirements. These algorithms are developed in close collaboration with interdisciplinary teams and are in part inspired by evolutionary processes in nature. As with bionic structures, the first step is to use only the material that is actually required for the topology of the component, and during fine-tuning in the second step, the component is reinforced only where necessary. This ultimately results in lighter and more rigid components as well as greater efficiency and improved vehicle dynamics.

“It’s impressive to see how WAAM technology has developed from research to become a flexible tool for not only test components but also series production components. The use of generative design methods enables us to make full use of design freedom and thus the potential of the technology. That was unthinkable just a few years ago,” said Karol Virsik, Head of BMW Group Vehicle Research.

Production processes can complement each other

Different additive production processes are not necessarily in competition with each other, rather they should be viewed as complementary. For example, laser beam melting will continue to be more advantageous than the WAAM process when it comes to the highest level of detail resolution. In terms of the possible size of the component and the deposition rate, however, wire arc additive manufacturing is superior. The BMW Group is initially planning centralised WAAM production of components in Oberschleißheim, in the future, production at other locations and the use of the technology by suppliers is also possible. Further, it would even be conceivable to produce individual components directly on the assembly line using this process and to manufacture different parts without new tools, simply by changing the software. Sustainability can also be further improved by increasing the use of recycled metals.

Steyr, Austria. The new halls for future e-drive production reached completion at the BMW Group site in Steyr. Construction began in September 2022, with the topping-out ceremony taking place exactly one year later. With some 60,000 square metres of production space, the 105 by 150-metre building was erected to a tight schedule. But now it’s standing. “The construction and installation of this production facility for Neue Klasse e-drives is running totally to plan. Now comes the next important stage, which is no less ambitious than the construction of the halls themselves,” explained Helmut Hochsteiner, head of electric drives at the BMW Group site in Steyr.

Approx. 300 items of plant and equipment worth over 500 million euros

Over the next few months, around 300 items of plant and equipment – many made to specification – will need to be installed, ready for pre-series production to launch as planned in July of this year. “The 300 machines are all shapes and sizes, from small, individual items to the over 30 metre-long ‘marriage’ station. Here, four robots and other systems will work in concert to fit the transmission to the main motor,” said Hochsteiner.

Klaus von Moltke, Senior Vice President of Engine Production at BMW AG and Plant Director of Steyr, outlined the economic dimensions of the project: “We are investing a total of more than 500 million euros in plant and equipment for Steyr, offering further confirmation of the BMW Group’s commitment to the site. Series production of e-drives for the Neue Klasse is scheduled for launch in the autumn of 2025.”

The first piece of plant was brought into the new assembly hall in the end of January. The ‘inaugural inhabitant’ is a crane that will lift power electronics components from the first floor – where inverter will be assembled in a clean-room – down to final assembly on the ground floor. Once the electronic parts have arrived, the inverter and e-drive will be ‘married’.

By 2030 the BMW Group will invest some 1 billion euros in total in e-drive production at its Steyr facility. The plant will manufacture over 600,000 e-drives a year alongside diesel and petrol units. Production of these will remain high as well, with combustion engines forming an important part of Steyr’s product portfolio well into the future.

Munich. A new era is dawning for BMW Group Plant Munich: from 2026, the iconic parent plant will produce the Neue Klasse sedan. Just one year later, the factory will manufacture nothing but all-electric models, making the Munich plant the first location in the BMW Group’s existing production network to have successfully completed the transformation to E-mobility from the end of 2027.

“The Munich plant is an excellent example of our ability to adapt. We are investing € 650 million here and will produce exclusively all-electric vehicles in our parent plant from the end of 2027,” says Milan Nedeljković, Member of the Board of Management of BMW AG, Production. “Last year alone, six all-electric models went into production. At the same time, we also set a production record, proving that we are simultaneously able to both deliver and shape the future in our production network.”

Peter Weber, Director BMW Group Plant Munich, adds: “Munich is the beating heart of BMW. The plant in Munich is innovative and adaptable. As in the 1960s, a Neue Klasse is again laying the foundation, on which our plant is reinventing itself. The fact that this comprehensive transformation is taking place at the same time as roughly 1,000 vehicles per day are currently being manufactured is common practice in Munich and is possible thanks to the outstanding performance of all our employees. We are delighted to be guiding the Munich plant into a fully-electric future – starting with the Neue Klasse sedan.”

Smooth transition to electromobility, as the era of combustion automobiles from Munich ends in 2027

BMW Group Plant Munich is a prime example of the fluent transition to the era of electromobility. In 2015, the first plug-in hybrid models from the BMW 3 Series were manufactured on the same production line as combustion vehicles. In 2021, the BMW i4 became the first all-electric vehicle to be produced on the same production line. Nowadays, every second vehicle that rolls off the production line has an all-electric drive system.

From 2026, production of the Neue Klasse in the Munich plant will initially run parallel to production of current models. A good year later, from the end of 2027, the BMW Group’s parent plant will be the first existing site in the global production network to manufacture exclusively all-electric vehicles, having been transformed accordingly. As such, the era of vehicles with combustion engines in Munich will draw to a close 75 years after the launch of the BMW 501 in 1952.

After the start in the new plant in Debrecen, Hungary, and in Munich, the Neue Klasse vehicles will also be produced in Shenyang, China, and San Luis Potosí in Mexico.

Extensive modifications offer long-term security for location

Over the course of a history stretching back more than 100 years, BMW Group Plant Munich has undergone many changes and repeatedly reinvented itself. Together with the conversion from manufacturing aircraft engines to automobile construction, the successful introduction of the Neue Klasse in the 1960s is a milestone in the list of changes throughout the company’s history.

At the moment, multiple large construction sites are evidence of the turnaround, as they pave the way for the arrival of the Neue Klasse from 2026. The € 650 million of investment comprises four buildings, including a new vehicle assembly line with logistics areas and a new body shop.

In order to create the space within the limited floor space at the plant in the heart of Munich, the traditional engine manufacturing has been moved to Hams-Hall in Great Britain and Steyr in Austria after roughly 70 years at the parent plant. 1,200 employees have been trained for different production strategies in Munich or have taken up employment at other locations in the production network.

As in the 1960s and all other changes since, the current transformation of BMW Group Plant Munich is taking place whilst production is still ongoing. Regardless of the construction work, roughly 1,000 cars roll off the production line every day, including BMW 3 Series and the BMW i4 – all on the same assembly line.

The extensive reorientation of the plant secures a long-term future for the site in Munich, and is also a significant investment in Bavaria as an industrial location.

Digitalisation at the Munich plant in accordance with the principles of BMW iFACTORY

The principles of BMW iFACTORY guarantee the utmost flexibility, excellent processes and outstanding integrability at all sites within the BMW Group – from the completely new plant in Debrecen to the parent plant in Munich, which is over 100 years old and at which the transformation is in full swing. BMW iFACTORY is synonymous with the superb production expertise throughout the entire production network. One important aspect is a comprehensive digitalisation with a holistic approach to the interaction between people, processes and systems. It optimises processes and supports employees with their work. The implementation takes place in three areas: data science, artificial intelligence (AI) and virtualisation.

Singapore. 2023 has been key for BMW Group Asia’s growth as a leader in the automotive market in Singapore. BMW started the year with the introduction of the first-ever BMW M3 Touring and new BMW 3 Series at the Singapore Motorshow, and went on to diversify its portfolio with the first-ever BMW XM, new BMW 3 Series Touring, new BMW i4 eDrive35, all-new BMW M2, all-new BMW M3 CS, new BMW X5, new BMW X6, all-new BMW 5 Series and its first-ever BMW i5. MINI also saw the launch of the MINI Convertible Seaside Edition and MINI Clubman Final Edition. To close off 2023, BMW Group Asia’s footprint within Singapore expanded even further with new showrooms, and a pop-up store.

“2023 was a thrilling year for BMW Group in Singapore,” said Lars Nielsen, Managing Director, BMW Group Asia. “With the introduction of 11 new BMWs and two new MINIs, our EV portfolio has increased to offer seven vehicles. Thanks to this, we have achieved 60% growth year-on-year in electric vehicle sales, which accounted for over 23% of total BMW Asia sales. Our luxury class vehicle sales recorded a 22% increase from 2022, mainly driven by the success of the BMW 7 Series. In addition to our existing presence centrally, we extended our dealer network to the eastern and western regions of Singapore. While some see the end of the year as a chance to wind down and enjoy the fruits of the last 12 months, BMW Group Asia, along with our partners, see it as an opportunity to strive further for excellence.”

“Thanks to our partners at Eurokars Auto and Performance Motors, new and existing customers can enjoy brand-new experiences when purchasing or servicing their BMW. Fans of MINI are also invited to MINI Pitstop by Eurokars Habitat, the first-ever MINI pop-up store in Singapore. Our success in 2023 was the result of the tireless work of all colleagues and partners, and I am proud of everything we have achieved together as a team!”

Nielsen added, “Our success in 2023 doesn’t just lie in Singapore either – the regional office recorded its highest ever sales volume across our markets, with sales of BMW M cars doubling, and our electric vehicle growth nearly quadrupling. Being headquartered in Singapore has of course given us the opportunity to grow in such strength within the Asia Pacific region, with the fast-paced nation acting as a lighthouse steering our markets to shore.”

BMW Eurokars Experience Centre.

One year on from the appointment of Eurokars Auto as the second official dealer of BMW vehicles in Singapore, the BMW Eurokars Experience Centre, spanning nearly 796m² and houses the country’s first Retail.Next showroom, was unveiled at the brand new Eurokars Centre focusing on M and Luxury vehicles. Located at 11 Kung Chong Road, the building serves as a flagship facility for Eurokars Group.

Retail.Next has been designed to provide a completely new and holistic experience for customers in every interaction that they have with the dealership. A stylish and consistent interior design, paired with green elements within the space, provide a harmonious journey for the customer and underline the brand’s sustainability and electrification credentials.

Eurokars Group is also expanding its presence into the western region of Singapore, with the BMW Eurokars Auto Service Centre to commence operations end February 2024. It will be housed at the Eurokars Aftersales Centre in 27A Tanjong Penjuru, bringing greater convenience to customers living in the area. 29 Leng Kee will be turned into a flagship BMW Eurokars Auto showroom, also encompassing the Retail.Next concept.

BMW Premium Selection.

Sime Darby Motors expands its reach to East Singapore with its certified pre-owned BMW dealership, BMW Premium Selection (BPS), located on the first floor of Sime Darby Motors’ new flagship building at 1 Ubi Road 4, offering the most comprehensive range of Certified pre-owned BMWs and pre-owned BMWs. BMW Motorrad is situated on the same level, with up to 18 motorcycles on display, a heritage showcase, service receptions, and accessories counter.

Performance Motors Service Centre.

A new Performance Motors Service Centre is implemented at 1 Ubi Road 4, providing BMW owners with the option of servicing their car closer to home. A contactless key drop-off service and bento boxes are available for those on-the-go, with complimentary shuttle buses servicing MacPherson and Ubi MRT stations for greater convenience.

The current Performance Motors Limited showroom at 303 Alexandra Road will undergo a refurbishing in 2024 to incorporate the Retail.Next concept as well.

MINI Pitstop.

Eurokars Habitat ended 2023 on the precipice of an exciting 2024 for MINI. Fans and enthusiasts are invited to visit MINI Pitstop, a pop-up store by Eurokars Habitat, located at the new One Holland Village shopping mall. Open from 11am to 9pm daily, everyone is welcome to browse from the MINI models on display and explore the MINI Lifestyle Collection, ranging from apparel to accessories. Test drives are also available.

Designed to reflect the BMW Group’s Retail.Next Concept, MINI Pitstop is an open-concept space, which facilitates a seamless customer journey through the MINI models, to the MINI Lifestyle Collection display, and the lounge area. In addition, curated furniture and the use of different textures and materials reflect the individuality and versatility of MINI. Everyone can look forward to exciting activations at MINI Pitstop in the coming months.

MINI Pitstop by Eurokars Habitat is located at #01-08 One Holland Village, 7 Holland Village Way, Singapore 275748.

Driving the future.

BMW Group Asia is poised to continue its growth in 2024 starting with the Singapore Motorshow, where the first-ever BMW iX1 and all-new BMW X2 will be launched. The MINI Concept Aceman will also be making its Southeast Asian debut, teasing the arrival of the latest MINI generation.

This year, customers will have greater convenience and flexibility when it comes to shopping or servicing their BMW or MINI with the planned opening of the following brand new retail / service concepts:

• Eurokars Auto Service Centre at 27A Tanjong Penjuru.
• Eurokars Auto BMW Showroom at 29 Leng Kee Road.
• Performance Motors BMW Showroom at 303 Alexandra Road.
• Eurokar Habitat MINI Showroom at 27 Leng Kee Road.

                                                                 -End-

Leipzig. The start of MINI Countryman production marks a number of firsts and milestones for BMW Group Plant Leipzig: for the first time, a MINI model is being made in Germany – on the same production line as the BMW 1 Series and 2 Series. It’s all made possible by the plant’s flexible structures and development. Over the last five years the BMW Group has invested €700 million to ready Leipzig for increased vehicle volumes and adapt it for MINI-specific requirements. By the end of 2024 the workforce in production will increase by over 900. In addition, the new MINI Countryman is a catalyst for innovations in sustainable production.

“By launching production of the MINI Countryman here in Leipzig, we are introducing multibrand operations to our flexible production system,” explained Milan Nedeljković, Board Member for Production. “Plant Leipzig also offers a number of highlights in terms of resource conservation in production, providing further evidence of the successful rollout of our long-term masterplan: the BMW iFACTORY.”

Seamless integration through flexible structures 

When it comes to production of the new MINI Countryman, the BMW Group is building on the skills and extreme flexibility of Plant Leipzig to forge new pathways in manufacturing. Seamlessly integrated into the production process, the MINI Countryman now rolls off the same assembly line as the BMW 1 Series, BMW 2 Series Gran Coupé and BMW 2 Series Active Tourer.

Thanks to its flexible assembly structures, Plant Leipzig is in a position to produce two brands with three different drives – combustion, plug-in-hybrid and fully electric – all on the same production line. The third-generation MINI Countryman will be available with a petrol, diesel or fully electric powertrain, with the high-voltage batteries for the MINI Countryman Electric also being made in Leipzig. It will reach dealerships on 17 February 2024.

Investments and recruitment to increase production volume

The BMW Group has invested some €500 million in Leipzig to increase production volume for new models. Since 2018 the bodyshop, paintshop, assembly and logistics have undergone extensive additions and upgrades, taking production capacity up from 250,000 units previously, to as much as 350,000 units a year at present.

To adapt the production system to MINI-specific requirements, the BMW Group invested around €200 million. Initially approx. 100 MINI Countryman cars a day will roll off the production lines, rising to 500 during the course of next year – in addition to the almost 1,000 BMW cars already coming out of the factory every day. This will not only secure existing jobs but also create up to 900 new ones in vehicle production alone.

Electromobility and MINI production drive development

Another important milestone in the development and extension of Plant Leipzig is its transition to electromobility. “Leipzig remains electric,” says a cheerful Petra Peterhänsel, Plant Director. “With the BMW i3 and i8, we were at the vanguard of e-mobility at the BMW Group, and from 2024, we will be producing our next fully electric car: the MINI Countryman Electric. We will manufacture the high-voltage batteries for it in-house as well.”

Starting next year BMW Group Plant Leipzig will run the entire production process for the current fifth generation of high-voltage batteries. This consists of three stages: cell coating, module production and battery assembly. The five cell coating lines, three module production lines and the first high-voltage battery assembly lines are all in the process of going into operation, with a second high-voltage battery assembly line scheduled for launch in 2024.

Capacity for e-component production has also been increasing, since 2021, making Plant Leipzig an important a supplier across the BMW production network. The parts are used in fully electric vehicles such as the BMW iX1, BMW i4, BMW i5 and BMW iX. E-component production in Leipzig currently employs over 800 people, and there are plans to develop it further, with investments totalling more than €800 million.

Sustainable materials and production 

The MINI Countryman Electric is a major step in the MINI brand’s transition to full electrification by 2030 and combines an electrified go-kart feel with a reduced environmental footprint. In developing the new model, the MINI brand’s responsible attitude was very much in the focus with regard to materials and production: chrome no longer features anywhere in the interior or exterior, and the light-metal alloy wheels are cast from up to 70 percent secondary aluminium. The permanently electrically excited synchronous motors are highly efficient and made entirely without rare earth minerals.

The interior is made purely from innovative, high-quality materials that are easy on the environment. The dashboard, door facias, floor covering and foot mats, for example, are made of recycled textiles. A high-quality alternative to conventional materials such as plastics, recycled textiles reduce CO₂ emissions along the value chain and require less water to manufacture.

Innovative painting method for contrast roof 

One of the striking design features of the MINI exterior is the contrast roof, which can be ordered in a different colour from the rest of the body. In the MINI Countryman it will be painted using a new, resource-friendly method known as overspray-free painting. Currently being readied for series operation, overspray-free painting does away with the excess paint – or overspray – generated by conventional painting methods and makes surfaces with more than one colour easier to produce, as they no longer require the laborious process of masking. Overspray-free painting also helps save CO₂ emissions, as exhaust air from the cabin requires less cleansing. Plus it requires considerably less conditioned air, i.e. air that is brought to a set temperature and humidity. As a result, less energy is needed to temper air and treat exhaust.

Another sustainable innovation operating at Plant Leipzig is the burner technology used to dry the paint on contrast roofs. Last year Leipzig became the first car plant in the world to pilot the new technology, which can run on not only natural gas but also hydrogen. The flexible burners can burn hydrogen (H2), natural gas (methane – CH4) or a mixture of the two and can even switch between them without having to halt operations. After successful tests, Plant Leipzig has now installed five hydrogen-capable bivalent burners for series operations, which are now being used for the contrast roof of the MINI Countryman. Plans are in place to convert further burners in the paintshop to bivalent operations.

Plant Leipzig – Built for sustainability

At Plant Leipzig, the focus has always been very much on efficient processes and a long-term strategy for energy generation and consumption, ever since planning began. “Sustainability is in the DNA of BMW Group Plant Leipzig. There’s one example that everyone can see: our four wind turbines, which generate electricity for the plant,” Petra Peterhänsel explained. They were erected in 2013 and deliver 10 MW (generating approx.  25 GWh/year). The second milestone came in 2017, when the battery storage farm went on stream. Equipped with up to 700 second-life high-voltage batteries from BMW i3 vehicles, it offers interim electricity storage for energy from the wind turbines and elsewhere, helping to optimise local energy management and stabilise the grid.

“Our vision at Plant Leipzig is to decarbonise production as far as possible by replacing fossil fuels with green hydrogen,” said Petra Peterhänsel, explaining the long-term focus of the facility. This will require sufficient green hydrogen from a grid. A regional hydrogen grid is currently in planning, with Plant Leipzig set to benefit.

+++ 100 students starting training in Debrecen +++ 6,500m² state of the art Training Centre for associates and students +++ Milestone on the road to NEUE KLASSE +++

Debrecen / Munich. The BMW Group has opened the Training Center at its new plant in Debrecen, Hungary. The company is investing more than one billion euros in the site, where series production for the first all-electric model of the Neue Klasse will start in 2025. The education and training of highly qualified employees is of particular importance.  

With the Neue Klasse, the BMW Group will introduce the next generation of BMW models. This combines the company's innovative strength in the central areas of electrification, digitization and circularity.

The opening of the Training Center at the future plant in Debrecen, Hungary, marks another milestone on the BMW Group's journey to start production of the Neue Klasse in 2025.

In the facility, equipped with the latest infrastructure, on an area of almost 6,500 square meters and with an investment volume of just under 20 million euros, employees of the BMW Group Plant in Debrecen as well as trainees and dual education students acquire the necessary skills for the production of the new generation of models.

During the opening, Ilka Horstmeier, member of the Board of Management of BMW AG, People and Real Estate, Labour Relations Director, emphasized: “The Neue Klasse is our promise for the future because it gives us the opportunity to completely rethink mobility and collaboration. We shape our transformation through People and Places together with our employees — they make the difference. With the start of the first 100 students and the opening of the Training Center here in Debrecen, we are underlining the relevance of education and training as a decisive factor for the future orientation of our company.”

By 2025, the number of trainees will rise to a total of up to 300. This makes it one of the largest apprentice training programs in all of Hungary.

The dual training program offered in collaboration with the Debrecen Vocational Training Center offers students the opportunity to acquire skills that can be the basis for an entire career. It is a three-year course in the areas of mechatronics, electronics, automotive mechatronics, and IT systems and applications. All these capabilities are important for future automotive production. The new training center offers state-of-the-art facilities and a high-tech learning environment. After successful completion of apprentice training, every trainee is offered an employment contract by the BMW Group or they take advantage of the opportunity to study further.

„We are pleased to welcome the first apprentices to our new Training Center. Within our facility we will teach them all about automotive production, our processes and the BMW culture“ said Hans-Peter Kemser, President and CEO BMW Group Plant Debrecen. „Our culture is the key for a successful future here in Debrecen. We are one plant, one team, which means that we count on each other and appreciate everyone’s contribution and knowledge“.

In addition to initiatives for students and trainees and offering new employment opportunities, the BMW Group will work with local and regional universities to support and implement art and cultural projects. This underlines the BMW Group's guiding principles of being a responsible corporate citizen and engaging with local communities.

“We are delighted that the BMW Group is bringing its latest technologies to Hungary and will produce its newest battery-electric model here in Debrecen in the future,” said Foreign and Trade Minister Péter Szijjártó at the event. “The Training Center will strengthen the cooperation between Hungary and Germany — the joint education and training program will offer young students an excellent perspective for the future.”

The training center at the BMW Group plant in Debrecen is one of the first fully completed buildings on the 400-hectare site that is in operation. The Communication Center will be the next major structure to be completed and in full use.

The BMW Group plant in Debrecen was planned and developed as an iFACTORY. It will be the first production plant in the world to be powered entirely by fossil-free energy. A significant portion of the required energy will be generated by a 50-hectare photovoltaic system directly on the factory premises.

The plant is designed for a production capacity of 150,000 units per year.

Munich/Parsdorf. A tiny piece of the future began rolling off the production line in Parsdorf today: 95 millimetres tall, cylinder-shaped, with a diameter of 46 millimetres. These are the new battery cell samples – like those that will be used in the models of the Neue Klasse from 2025 onwards – being produced at the new Cell Manufacturing Competence Centre (CMCC) in Parsdorf. The BMW Group is thus positioning itself to ramp up electromobility efficiently and showcasing its leading role in battery cell technology.

“With the Cell Manufacturing Competence Centre, we are strengthening Germany’s capacity for innovation,” explained Milan Nedeljković, member of the Board of Management of BMW AG, responsible for Production. “In this way, we are making an important contribution to the quantum leap in technology in the Neue Klasse.”

“Production of battery cell samples in Parsdorf marks the next logical step in our battery cell strategy,” said Frank Weber, member of the Board of Management of BMW AG, responsible for Development. “The Cell Manufacturing Competence Centre is the perfect complement to our existing Battery Cell Competence Centre in the north of Munich. Development takes place there, then we scale the best product towards a series process in Parsdorf. Thanks to cross-divisional collaboration, we are able to link product and process in a unique way.”

The CMCC in Parsdorf will enable the BMW Group to span the whole cell value creation process. With this know-how, the company is setting benchmarks for production, quality, performance, costs and environmental standards, which it is implementing in close cooperation with its partners for standard production of battery cells. At its battery cell competence centres in Munich and Parsdorf, the BMW Group is systematically pursuing future milestones, such as the ramp-up of the sixth generation of BMW electric drive trains and development of all-solid-state batteries (ASSB). About 80 employees work at the 15,000-square-metre Cell Manufacturing Competence Centre, which has benefited from a total investment of around 170 million euros. The German Federal Ministry of Economic Affairs and the Bavarian Ministry of Economic Affairs, Regional Development and Energy are supporting the project within the framework of the European funding process IPCEI (Important Projects of Common European Interest).

Recycling at the CMCC: Keeping materials in the loop

Raw materials are among the significant cost factors for cell production. Efficient and responsible use of raw and carrier material is therefore necessary and makes sense from both an environmental and economic perspective. At the new CMCC, experience will be gained from all processes and the lessons learned analysed to further optimise the use of resources. Residual materials from the production process will be collected at the CMCC, sorted and fed back into the cell production cycle. In addition to working on the cell manufacturing process, BMW Group experts are also focusing on reusing materials and components from the whole battery after its initial use in the vehicle.

At the Battery Cell Competence Centre (BCCC) in Munich, the first battery cells made from 100% recycled and/or secondary (battery-grade) cathode material have been manufactured and tested using state-of-the-art characterisation methods. Our cell suppliers are already delivering battery cells containing secondary raw materials (e.g. nickel) from various used-battery sources (incl. production waste). The long-term aim of the BMW Group is to reuse all raw materials in recyclable high-voltage batteries.

How the cell is created: Production steps for sample manufacturing at the CMCC

Cell manufacturing begins with electrode production. Here the base material, comprising, for example, graphite for the anode and nickel oxides for the cathode, with binders and solvents, is metered and mixed in a precisely measured ratio. This creates the so-called “slurry” – which means wafer-thin metal foils are coated and then compressed after drying. In technical jargon, this is referred to as “calendering”. The highest level of precision is required: The foil is just a few micrometres thick – in other words, thinner than the threads of a spider web, while the coating is in the micrometre range. During cell assembly, the coated foils, referred to as calendered electrodes, are wound into so-called “jelly rolls” using the separator and inserted into the cell housing. The cells are filled with electrolyte, then charged for the first time and finally checked for functionality and quality.

CMCC Parsdorf: Buildings with a focus on the environment

The CMCC in Parsdorf is built to high environmental standards. An immission control approval procedure has been carried out for the technical installations used in battery cell production – ensuring that the company complies with all requirements and guidelines. The CMCC will also operate fossil-free, relying on electricity produced using renewable energy, including from photovoltaic systems on the roof of the building. The building will also be supplied with regenerative heat produced using state-of-the-art groundwater and air heat pumps.

Sixth-generation BMW battery technology: New cell format and enhanced cell chemistry

The battery cell is responsible for electric vehicles’ core properties: range, driving performance and charging time. With the new BMW round cell specially designed for the electric architecture of the Neue Klasse models, it will be possible to significantly increase the range of the top model by up to 30 percent (according to WLTP).

The new BMW round cells come with a standard diameter of 46 millimetres and two different heights of 95 millimetres and 120 millimetres. Compared to the prismatic cells of the fifth BMW battery cell generation, the nickel content of the sixth-generation BMW round cells will be higher on the cathode side, while the cobalt content will be reduced. On the anode side, the silicon content will be increased. As a result, the cell’s volumetric energy density will improve by more than 20 percent.

Battery, drive train and charging technology in the Neue Klasse will have a higher voltage of 800 volts. Among other things, this will optimise how energy is supplied to direct current high-power charging stations, which can achieve a much higher charging capacity with a current of up to 500 amperes – thus reducing the time it takes to charge from ten to 80 percent by up to 30 percent.

Reducing the carbon footprint of battery cell production by up to 60 percent

The BMW Group is particularly focused on keeping the carbon footprint and resource consumption of production as low as possible, starting in the supply chain. For standard production of battery cells, the cell manufacturers commissioned will use cobalt, lithium and nickel containing secondary material. Together with the commitment by its cell suppliers to use only green power from renewable energies in production, the BMW Group will reduce the carbon footprint from battery cell production by up to 60 percent, compared to the current generation of battery cells.

Dingolfing. Exactly 50 years ago, cars built by the Bavarian premium manufacturer began rolling off the assembly line at BMW Group Plant Dingolfing. Since 27 September 1973, the people who work at what is now the BMW Group's largest European plant have produced Sheer Driving Pleasure more than twelve million times. “This anniversary is naturally an opportunity to look back on this plant’s amazing success story – but it is also an excellent reason to look ahead to the future with optimism,” said Plant Director Christoph Schröder, at a ceremony attended by representatives from business and the political sector. “Because this plant will continue to be of tremendous importance to the BMW Group, to the region and to many thousands of people.”

12 million BMW cars in 50 years

The figures presented to guests by Plant Director Christoph Schröder and Stefan Schmid, Chairman of the Dingolfing Works Council, in the light-hearted speech they delivered together, are impressive. In purely mathematical terms, with 12 million vehicles produced over the past five decades, that means a BMW rolled off the Dingolfing assembly line every 60 seconds: from the very first Iberian Red BMW 520 on that Thursday back in 1973, right up to today.

Almost two thirds of the production volume comes from Dingolfing’s core model series, the BMW 5 Series: The eighth generation, which has been in production since early July, will be hitting showrooms in the coming days. The range of models produced has gradually expanded over the decades and, today, with vehicles from the BMW 4 Series, 5 Series, 6 Series, 7 Series and 8 Series, as well as the BMW iX and BMW M GmbH models, it has reached a dimension that sets the benchmark for the whole automotive industry.

However, Dingolfing’s carmakers not only excel in large-scale production, with the highest level of efficiency and precision, but also in craft-scale manufacturing. The 99 BMW 8 Series models designed by American artist Jeff Koons in 2022, the 50 recently-delivered highly exclusive BMW 3.0 CSL and the BMW i7 Protection, the world's first fully-electric security vehicle, all testify to this outstanding expertise. The body shop also meets the highest standards of quality and craftsmanship required for all Rolls-Royce models in Unterhollerau.

Plant Dingolfing as job engine for the region

Plant Dingolfing is closely associated with the economic rise of the eastern Bavaria region. “In the past ten years alone – including permanent jobs for apprentices and temporary staff – we have hired 12,000 people here at the site,” said Stefan Schmid. The Works Council Chairman also announced that the number of new apprentices starting their training at the Dingolfing location in the coming year will increase to 350, with a view to the planned site in Irlbach-Straßkirchen. “We will continue to be the BMW Group's largest vocational training facility.”

The decisive guarantee of this 50-year success story is the continuing adaptability of the Dingolfing workforce. “Pioneers never stand still,” said Schröder, underlining that: “We have stayed young in our thinking, we are technology leaders with our processes and our products are clearly geared towards the future.” The plant is shaping the transformation towards e-mobility in a way that is “strategically smart, forward-looking and proactive”. With its strategy of a highly flexible production system that allows all drive train variants to be built efficiently on one line, according to market demand, the plant is ideally positioned, Schröder explained: “We have every reason to be optimistic about the future.”

Three series launches of electric models in two years

With the BMW iX, i7 and i5, Plant Dingolfing has celebrated the premiere of three fully-electric models within the space of two years. With the start of production for the BMW i5 Touring in the coming year, Schröder expects fully-electric vehicles to account for about 40 percent of Dingolfing's total production in 2024. “I am confident production volumes will climb to well over 300,000 units in the next year as the entire 5 Series family becomes available.”

Schröder also believes digitalisation will become even more important, explaining that both the product and the production process will increase in complexity – all of which needs to be controlled and validated. “Dingolfing is doing an excellent job,” explained the plant director: “We are leaders in our industry, with a large number of projects, such as Automated Driving In-Plant, AI-based camera systems and smart logistics applications.” In many respects, a vehicle plant has been a tech company for years. “That is why we are deliberately strengthening our IT functions – for example, through the Innovation Hub, which the BMW Group established together with Microsoft, Intel and NTT at the Dingolfing training centre.”

The BMW Group in Dingolfing – more than just a car plant.

In addition to cars, vehicle components such as pressed parts and chassis and drive systems are also produced in Dingolfing. Component plant 02.20 is home to the Competence Centre for E-Drive Production, with about 2,400 employees, which supplies the BMW Group’s vehicle plants worldwide with electric motors and high-voltage batteries for production of plug-in hybrids and fully electric models. Since 2015 alone, more than one billion euros have been channelled into expanding the component plant, which is capable of producing electric powertrain components for more than 500,000 electrified vehicles.

Another important element of the Dingolfing location is the so-called Dynamics Centre, the heart of the BMW Group’s central aftersales logistics, which provides the global BMW and MINI retail organisation with original parts and accessories.

The BMW Group recently invested several hundred million euros in the site each year – with the next investments in future products and technologies already becoming apparent. “Because, of course, the models of the future being built in Dingolfing will also benefit from the innovations and technology clusters of the NEUE KLASSE,” says Schröder. The assembly plant for high-voltage batteries planned in Irlbach-Straßkirchen will be an essential element of this. “On the one hand, it will secure the jobs of thousands of people; on the other, it will enable the successful transition of Plant Dingolfing towards electromobility.”

If you have any questions, please contact:

Julian Friedrich, BMW Group Plant Dingolfing, head of Communications

Telephone: 49 8731 76 22020, Email: Julian.Friedrich@bmw.de

Thomas Niedermeier, BMW Group Plant Dingolfing, Communications

Telephone: +49 8731 76 27666, Email: Thomas.Niedermeier@bmw.de

Media website: https://newsroom.bmwgroup.com/global/en www.bmw-werk-dingolfing.de

Instagram: https://www.instagram.com/bmwgroupwerkdingolfing/

Email: presse@bmw.de

BMW Group Plant Dingolfing

Plant Dingolfing is the BMW Group’s largest European production site.

Over 1,500 BMW 4 Series, 5 Series, 6 Series, 7 Series and 8 Series cars, as well as the fully-electric BMW iX, come off its production lines every day. Around 282,000 vehicles were built at the plant in 2022.

More than 18,000 people currently work at the site and 850 apprentices are being trained in 15 occupations. This makes the BMW Group site in Dingolfing not only the region's biggest employer by far, but also one of the country's largest industrial production sites and vocational training facilities.

In addition to cars, vehicle components such as pressed parts and chassis and drive systems are also produced in Dingolfing. Component plant 02.20 is also home to the company-wide Competence Centre for E-Drive Production, which supplies the BMW Group’s vehicle plants worldwide with electric motors and high-voltage batteries for production of plug-in hybrids and pure electric models.

The car bodies for all Rolls-Royce models are also built at the site. The so-called Dynamics Centre, a large storage and transshipment facility at the heart of the BMW Group’s aftersales logistics, provides the global BMW and MINI retailer organisation with original parts and equipment.