Munich/Zagreb. The BMW Group and the Croatian University of Zagreb’s Regional Centre of Excellence for Robotic Technology (CRTA) continue to advance joint research in battery cell production. The “Insight” research project will develop and implement practical AI models to optimise battery cell production at the BMW Group. The research project covers the entire battery cell value chain: from electrode production to end-of-line testing and in-house developed direct recycling.

How the research project saves raw materials, costs and time

At the Battery Cell Competence Centre (BCCC) in Munich, the BMW Group is developing battery cells for future generations of high-voltage batteries. As part of this process, numerous test series are conducted, which by their very nature require significant time and material investment. At the same time, these tests tie up manufacturing equipment and laboratory capacity. This is where the “Insight” research project comes in: Its artificial intelligence network uses existing test data, as well as real-time data from ongoing production, to accurately predict battery cell process parameters and performance data. As a result, the duration and number of test series can be significantly reduced, while maintaining or improving quality. In this way, the newly developed AI systems reduce the material and time required in individual process steps by more than 50 percent.

Other cell production use cases

The research project’s prediction models not only reduce the number of test series but also support final approval of battery cells. Following initial charging at the end of production, the cells must be stored for a defined period at precisely specified temperatures before they can be installed in a battery housing. This phase, also referred to as the “quarantine”, requires corresponding storage capacity. However, the research project’s AI systems are able to conduct a full analysis of the battery cells in advance, potentially eliminating this process step in the future.

Research collaboration combines theory and practice

Since the project was launched in 2024, the BMW Group and the University of Zagreb have been developing joint solutions using artificial intelligence to improve battery cell production. To this end, doctoral candidates and students at the University of Zagreb are collating and structuring available production data and using it to create AI models that can identify specific patterns. These AI models then make predictions that further optimise production performance, quality and costs. “We are working on scaling the newly developed AI models from the prototype environment,” explains Christian Siedelhofer, head of Technology Development Lithium-Ion Battery Cells at the BMW Group. One option would be to enable cell manufacturers. “We are also examining to what extent these models are suitable for additional use cases within our production network.”

Win-win through knowledge sharing

The University of Zagreb contributes expertise in mechanical engineering, electrical engineering and computer science to the project. Ongoing knowledge sharing benefits both partners: The University of Zagreb provides the BMW Group with access to the latest research findings, while its doctoral candidates and students have the opportunity to apply their theoretical knowledge in practice.

Development of young talent

Another aspect of the cooperation is the development of young talent. “Our joint project gets doctoral candidates and students interested in AI and battery cells and the exciting work we do at our Battery Cell Competence Centres,” says Stefan Kerscher, head of Technology Development Battery Cells at the BMW Group. “We are delighted when young talents decide to embark on a career with our company.” The cooperation offers students intensive mentoring and the opportunity to expand their professional network across the industry, enhancing their attractiveness on the job market and opening up outstanding career opportunities. The cooperation between the BMW Group and the University of Zagreb strengthens the innovation capability and competitiveness of both partners.

Battery cell expertise along the entire value chain

The BMW Group consolidates its battery cell know-how at its Competence Centres in Munich, Parsdorf and Salching. The Battery Cell Competence Centre (BCCC) in Munich houses research and development for the battery cells of the future. The best battery concept from the BCCC will be produced under near-series conditions at the Cell Manufacturing Competence Centre (CMCC) in Parsdorf. Close cross-divisional collaboration between Development, Purchasing and Production integrates product and process in a unique way. In addition to producing sample cells, the BMW Group is also focusing its efforts on the reuse of materials. As part of this process, the company has put into service a Cell Recycling Competence Centre (CRCC) in Salching, Lower Bavaria, together with Encory GmbH, which will implement the innovative direct recycling concept. The intellectual property for the recycling method is owned by the BMW Group.

Munich/Salching. The new Cell Recycling Competence Center (CRCC) in Salching in Lower Bavaria has now been officially commissioned – marking a major step forward in implementing innovative direct recycling as a joint project between the BMW Group and Encory GmbH. For construction and operation of the new Competence Center, the BMW Group and Encory are relying on regional partners.

Innovative direct recycling enables reuse of battery raw materials

Direct recycling allows residual materials from battery cell production, including complete battery cells, to be mechanically dismantled. The raw materials are not entirely reverted to their original state, but are instead “directly” fed back into the cell production cycle. This direct recycling methodology, developed by experts from the BMW Group, therefore eliminates the conventional, energy-intensive chemical or thermal processing previously required. At the new CRCC, direct recycling will be scaled up and introduced in stages until, once fully operational, the annual volume of battery cell material recycled will be in the mid-double-digit tonne range. Going forward, the recovered raw materials will be directly reused in pilot production of battery cells at the company’s own Cell Manufacturing Competence Center (CMCC) in Parsdorf.

Direct recycling: A process for the future

“Our direct recycling process puts us at the forefront of the industry,” explains Markus Fallböhmer, SVP of Battery Production at BMW AG. “This technology has tremendous potential to further optimise battery cell production.” It is also conceivable that, for the first time, cell manufacturers could be enabled to use direct recycling in series production.

Joint venture runs Competence Center – IP remains with BMW Group

An existing hall in Salching in Lower Bavaria (Straubing-Bogen district) will be used for the new Competence Center. In addition to the production area and warehouse space of around 2,100 m², the building also offers just under 350 m² of offices and break rooms, as well as photovoltaic systems on the roof. While the Competence Center will be built and operated by Encory GmbH, the intellectual property for the recycling method is fully owned by the BMW Group. As a joint venture between the BMW Group and the Interzero Group, Encory will develop and implement logistics and consulting solutions, including for recovery, recycling and reconditioning of vehicle components. Both partners hold a 50-percent stake in the company. The new Competence Center will employ about 20 people.

Strong partners from the region

With the exception of one Swiss company, only German firms were contracted for the construction and operation of the Competence Center. Nearly half of these companies are located within a 100-kilometer radius of Salching.

Optimal location for new Competence Center in Bavaria

The BMW Group consolidates its battery cell expertise at its Competence Centers in Munich, Parsdorf and Salching. The Battery Cell Competence Center (BCCC) in the north of Munich offers state-of-the-art labs and research facilities for developing the battery cells for next-generation high-voltage batteries and producing them in small quantities. The best battery cell from the BCCC will be scaled up for series processes on a pilot line at the Cell Manufacturing Competence Center (CMCC) in Parsdorf. Recycling of surplus material from pilot production in Parsdorf will take place at the new Cell Recycling Competence Center (CRCC) in Salching. The recovered raw materials will then be reused in cell production, ensuring short distances between all Competence Centers and preventing valuable raw materials from being lost. Following on from the BCCC and CMCC, the CRCC thus represents the next step in the BMW Group’s battery cell strategy on the road to the circular economy.

Circular economy at the BMW Group

The BMW Group views the circular economy as one of the key issues in shaping more resource-efficient mobility. Its approach is aimed at finding the best ways to keep materials in the cycle – ensuring that resources are not lost, but retain their value for long-term use. The BMW Group applies the principles of Re:Think, Re:Duce, Re:Use and Re:Cycle. From vehicle design and production, to recycling and reuse, everything is geared towards ensuring that vehicles can serve as a source of raw vehicles at the end of their use phase. The BMW Group is taking steps to increase the percentage of recycled materials. It returns selected production residues to the material supplier or material processor, enabling their recovery and reintroduction into a new manufacturing process. In this way, recycled and reused materials are already making their way into BMW Group vehicles today. The circular economy requires holistic thinking – from product design, all the way through to vehicle recycling. 

Munich/Parsdorf. With the Neue Klasse, the BMW Group is ushering in a new era of pure electric driving, starting series production end of 2025. The high-voltage battery is a key component in any electric vehicle. Before large-scale series production can begin, manufacturing processes must be developed and pre-series batteries put through their paces. This takes place at the BMW Group’s pilot plants for high-voltage batteries in Parsdorf and Hallbergmoos and at the Research and Innovation Centre (FIZ) in Munich. “Our pilot plants for high-voltage batteries are strengthening Germany’s capacity for innovation,” says Milan Nedeljković, Member of the Board of Management of BMW AG responsible for Production. “They are laying the groundwork for the new series plants worldwide, ensuring a smooth ramp-up of high-voltage battery production.” To produce high-voltage batteries for the sixth generation of BMW eDrive (Gen6), the company is establishing five assembly sites across three continents: in Irlbach-Straßkirchen (Lower Bavaria), Debrecen (Hungary), Shenyang (China), San Luis Potosí (Mexico) and Woodruff (USA).

Quality is key: Consistent zero-defect approach
For the in-house developed Gen6 high-voltage battery, the BMW Group is implementing intelligent, state-of-the-art production processes using the latest technologies. “For production of our high-voltage batteries, we are pursuing a consistent zero-defect approach,” explains Markus Fallböhmer, head of Battery Production at BMW AG. “Highly intelligent, AI-supported quality checks are integrated into the production process to help us achieve this.” Because quality is key: In bodies for the Neue Klasse, the high-voltage battery serves as a structural component (“pack to open body”). The new cylindrical round cells are integrated directly into the high-voltage battery (“cell to pack”). With its innovative production processes, BMW Group’s pilot and series plants are setting new industry standards for battery production. Examples include, among the consistent zero-defect approach, the use of digital production twins for tasks such as employee training, as well as leveraging expanded AI databases to optimise supply and production logistics. All production steps undergo seamless in-line monitoring with comprehensive data storage, enabling maximum process stability and continuous data-based optimisation.

Pilot plants up close: Parsdorf, Hallbergmoos and Munich (FIZ)
The largest pilot plant for Gen6 high-voltage batteries is located in Parsdorf, where over 350 employees have been building initial prototypes since 2023. Since mid-2024, some of the high-voltage batteries produced there have already been delivered to the vehicle plant in Debrecen, Hungary, where they are installed in test vehicles for the Neue Klasse. A pre-series plant for high-voltage batteries is also located near Munich Airport. Since summer 2024, the site in Hallbergmoos has been developing manufacturing technologies for high-voltage battery assembly. Around 200 employees are working at this small-scale battery factory. The Hallbergmoos site serves as a model for the series production at Plant Woodruff near Spartanburg, South Carolina, US. At the Munich Research and Innovation Centre (FIZ), another 200 employees are manufacturing and testing prototypes and smaller module variants of the high-voltage battery. Several floors of the recently opened Aeroacoustics and E-drive Centre (AEZ) are dedicated to this work.

Series launch of five battery plants in under two years
The systems and processes developed at the Bavarian pilot plants will be rolled out to the series plants worldwide. Within less than two years, series production will ramp up at five locations across three continents. In line with its "local-for-local" principle, the BMW Group has positioned its Gen6 high-voltage battery assembly sites as close as possible to its vehicle plants. This approach safeguards production, even in the event of unforeseen political and economic developments. It will also strengthen existing production sites, while preserving and creating jobs. Series production of the BMW iX3, the first model of the Neue Klasse, will get underway at Plant Debrecen late this year, alongside high-voltage battery manufacturing at the same site. The launch in Debrecen will be followed by the battery assembly plants in Shenyang, Irlbach-Straßkirchen, Woodruff and San Luis Potosí.

How the BMW Group builds Gen6 high-voltage batteries
The BMW Group sources battery cells for its high-voltage batteries from leading cell manufacturers, who produce the cells to the company's specifications. The highest technical standards apply. Upon receipt of goods, additional measurements – such as voltage checks – are carried out. Next comes cell clustering, where the battery cells are connected to coolants. 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 in-line 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 foam thus 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 to ensure quality, safety and function.


If you have any questions, please contact:

Corporate Communications

Christian Marxt
Press spokesperson, Production Network, Powertrain and High-Voltage Batteries
Cell phone: +49-151-601-79158
Email: Christian.Marxt@bmwgroup.com

Sandra Schillmöller
Head of Communications Production Network BMW Group
Cell phone: +49-151-601-12225
Email: Sandra.Schillmoeller@bmwgroup.com

Media website: https://newsroom.bmwgroup.com/global/en
Email: presse@bmwgroup.com