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Munich. With the new BMW X5, the BMW Group is systematically extending its holistic approach to sustainability to additional vehicle derivatives. The aim is to further optimise the entire vehicle lifecycle and minimise its carbon footprint – from the supply chain and production, through to the use phase and, ultimately, recycling.

Supply chain decarbonisation as key lever
Targeted decarbonisation throughout the supply chain is a key lever for reducing CO₂e emissions. The BMW Group is focusing in particular on renewable energy and secondary materials, as well as product and process innovations. Its holistic approach to sustainability is being applied across all X5 drivetrain variants.
The impact of this approach is reflected in the CO₂e reductions achieved: during the product development process, CO₂e emissions of the BMW X5 were reduced by around 40 percent.[1][2]
A further advance is the increased use of CO₂e-reduced flat steel for the body. Around 50 percent of the flat steel used in the BMW X5 is electric arc furnace steel (EAF steel) with a high proportion of secondary material, produced using renewable energy. The high share of CO₂e-reduced flat steel is the result of close, long-standing collaboration with local suppliers in North America.

Systematic use of secondary materials
The new BMW X5 achieves a high proportion of secondary raw materials, even in heavy-duty components. These include aluminium suspension components such as wheel rims, swivel bearings, wheel supports, rear axle supports and brake callipers, which are manufactured using renewable energy for both electrolysis and production. The aluminium used for the doors of the new BMW X5 contains 35 percent recycled and closed-loop material from BMW Spartanburg’s press shop. The base material used for the yarn of the headliner fabric is made from 100 percent recycled PET. In the battery-electric BMW iX5 60 xDrive, around one third of the total vehicle is made up of secondary raw materials, equivalent to a weight of 940 kilograms.[3]

Gen6 battery cells with reduced carbon footprint
The Gen6 battery cells used in the BMW iX5’s high-voltage battery include a high proportion of secondary materials in the cobalt, lithium and nickel content. Renewable energy is also used in the production of anode and cathode materials, as well as in cell manufacturing. Compared with the Gen5 cell used in the BMW iX, CO₂e emissions have been reduced by around 28 percent per watt-hour.

Efficiency during use phase
With its EfficientDynamics technology package, the BMW Group optimises vehicle efficiency across all relevant subsystems during the use phase. This includes aerodynamics, lightweight construction, low rolling resistance wheels and tyres, and overall energy management. EfficientDynamics has been used by the BMW Group across all drive technologies since 2007. The new fully electric BMW iX5 also features the familiar “Heart of Joy” from the BMW iX3 and BMW i3, with the BMW Dynamic Performance Control driving stack developed entirely in-house. With effortless, confident drivability and a particularly smooth stopping experience, the system also enhances efficiency: during deceleration, more energy is recovered through recuperation in significantly more driving situations, right down to a standstill.

CO₂e advantage achievable after approximately one to two years of use
Comprehensive decarbonisation measures across the supply chain, production and use phase result in an early breakeven point. Depending on the drivetrain variant, annual mileage and source of the electricity used for charging, the new BMW iX5 60 xDrive achieves a CO₂e advantage over a comparable model with an internal combustion engine after approximately one to two years of use.

Production at largest BMW Group plant
The BMW Group’s holistic approach to sustainability also extends to vehicle manufacturing at its largest production site, Plant Spartanburg. All external power required for production at BMW Group Plant Spartanburg comes from renewable sources.
Between 2006 and 2025, energy consumption per produced vehicle decreased by 66 percent. The volume of waste sent to landfills was also reduced by 88 percent over the same period. The newly built high-voltage battery assembly plant in Woodruff, which is connected to the main plant, runs entirely without fossil fuels in normal operation.

TÜV-validated Product Carbon Footprint publicly available
The BMW Group will publish the Product Carbon Footprint for the BMW X5, validated by the German Technical Inspection Association (TÜV), to accompany the series launch. The report, including the underlying calculation methodology, will be publicly available. In this way, the BMW Group provides transparency regarding the raw materials used and CO₂e emissions across the vehicle’s entire lifecycle.

If you have any questions, please contact:

BMW Group Corporate Communications

Dr. Cornelia Bovensiepen, Head of Communications Product Sustainability

Telephone: +49 151 601 94935

Email: Cornelia.Bovensiepen@bmw.de

Media website: https://newsroom.bmwgroup.com/global/en

Email: presse@bmwgroup.com

The BMW Group

With its four brands, BMW, MINI, Rolls-Royce and BMW Motorrad, the BMW Group is the world’s leading premium manufacturer of automobiles and motorcycles and also provides premium financial services. The BMW Group production network comprises over 30 production sites worldwide; the company has a global sales network in more than 140 countries.

In 2025, the BMW Group sold 2.46 million passenger vehicles and more than 202,500 motorcycles worldwide. Profit before tax in the financial year 2025 was €10.2 billion on revenues amounting to €133.5 billion. As of 31 December 2025, the BMW Group had a workforce of 154,540 employees.

The economic success of the BMW Group has always been based on long-term thinking and responsible action. Sustainability is a key element of the BMW Group’s corporate strategy and covers all products – from the supply chain through production to the end of their useful life. 

www.bmwgroup.com

LinkedIn: http://www.linkedin.com/company/bmw-group/

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

Facebook: https://www.facebook.com/bmwgroup

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Munich. In line with its sustainability strategy, the BMW Group is once again systematically leveraging product sustainability innovations in the new BMW 7 Series. This is evident, for example, in the use of a new battery cell technology and a higher percentage of secondary material in the wheel rims. These measures represent a targeted further development, applying proven sustainability approaches to another BMW model.

Sixth-generation (Gen6) battery cells in the new BMW i7: Measures to reduce CO₂e in core component.
Essential levers for reducing supply chain CO₂e emissions include increased use of secondary materials and renewable energies, in combination with selected product and process innovations.
Gen6 battery cells for the BMW i7’s high-voltage battery are manufactured exclusively using energy from renewable sources. The same applies to production of the necessary anode and cathode active material. Cell production also relies in part on secondary raw materials for the lithium, cobalt and nickel required. This reduces the overall supply chain CO₂e footprint of the Gen6 battery cell in the new BMW i7 60 xDrive by approximately 33 percent compared to the previous Gen5 cell used in the BMW i7 to date.

Aluminium wheels with high percentage of secondary raw materials.
From 2026, selected rim designs for the BMW i7 will be available with 70 percent secondary aluminium. Electrolysis of the remaining primary aluminium, as well as wheel rim production, is carried out in part using renewable energy. All components with a high percentage of secondary raw materials meet the BMW Group’s same strict quality standards, while also contributing to resource efficiency.

Enhanced efficiency during use phase.
With its EfficientDynamics technology package, the BMW Group optimises vehicle efficiency across all relevant subsystems during the use phase. This includes aerodynamics, lightweight construction, rolling resistance and overall energy management. EfficientDynamics has been used by the BMW Group across all drive technologies since 2007.

Production at BMW Group Plant Dingolfing.
All model variants of the new BMW 7 Series Sedan are produced at BMW Group Plant Dingolfing. The facility in Lower Bavaria, the Group’s primary plant for BMW luxury cars, increasingly relies on renewable energy for electricity and heating. 100 percent of its external electricity comes from renewable sources, some of which is also generated directly on site. In late 2025, an approximately 100,000-square-metre rooftop photovoltaic system with an output of almost 11 MWp was commissioned at the facility. In addition, a biomass heating plant went on-stream late last year to ensure that locally-produced heat is partially supplied from renewable energy sources.

In line with BMW Group’s sustainable development goals.
The BMW Group’s commitment to the Paris Climate Agreement and to reaching “net zero” no later than 2050 is an integral part of its holistic 360° approach to sustainability, which is anchored in its corporate strategy. The BMW Group has set itself ambitious science-based CO₂e targets for the coming years and intends to reduce its CO₂e emissions by a total of at least 40 million tonnes from 2019 levels by 2030.

Transparency through BMW Vehicle Footprint.
The BMW Group has published its vehicles’ Product Carbon Footprint, as validated by the German Technical Inspection Association (TÜV), in the so-called Vehicle Footprint for several years. This report is publicly available here for all drive trains of the new BMW 7 Series from the start of production and can also be accessed in the My BMW app. In this way, the BMW Group creates transparency around the percentage of secondary materials and CO₂e emissions throughout the vehicle’s lifecycle.

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Munich. In the BMW i3, as with the BMW iX3, the BMW Group applies a 360° approach to sustainability. At its core is decarbonisation throughout the entire vehicle lifecycle – from product development through the supply chain and production to the end of the use phase. In this way, the second Neue Klasse model also contributes to achieving the ambitious, overarching CO₂e targets the company has set itself.

CO₂e benefits already after 1-2 years of use.
Depending on the drive train variant, annual mileage and source of the electricity used for charging, the new BMW i3 50xDrive already achieves a CO₂e advantage over a comparable model with an internal combustion engine after one to two years of use[1].

Decarbonisation in the supply chain.
Targeted decarbonisation is a key starting point for reducing CO₂e emissions throughout the supply chain. The use of renewable energies, the increasing share of secondary material, and product and process innovations – for example, in the Gen6 cell and high-voltage battery – contribute to a significant emissions reduction across the entire supply chain.
The results of this systematic approach are demonstrated by the emission reductions achieved: Specific measures during product development of the BMW i3 lowered supply chain CO₂e emissions by about a third.[2]

Innovative materials and technologies for interior and exterior.
The “Design for Circularity” principle is also systematically applied in the new BMW i3. The concept incorporates gradually increased use of secondary materials, targeted reduction of material selection and optimised dismantling capability.
For example, the BMW i3 uses 30 percent recycled plastic in its front bumper trim. At the same time, the number of different materials used for the entire bumper, excluding mounted parts, was reduced from 15 to 7, compared to the predecessor model (seventh-generation BMW 3 Series). Due to the high use of a plastic particularly suitable for recycling, the proportion of recyclable plastic was increased from approximately 46 percent in the predecessor to about 85 percent[3]. This enables the recovery of high-quality plastic recyclates from the vehicle.
Another example of how the “Design for Circularity” principle is implemented in the new BMW i3 is the Econeer seat covers offered as part of the “Essential” equipment line, which are made from a recyclable textile composite. The basic material for the upper fabric is 100-percent recycled PET. The use of recycled PET granulate – as the base material for the polyester yarn required – significantly reduces CO₂e emissions and water consumption during manufacturing compared to primary material. The dismantling capability of the seat cover has also been improved to facilitate a material-specific separation at the end of the lifecycle.

Use of secondary materials in the new BMW i3.
The new BMW i3 consists of approx. 30 percent secondary materials in total[4]^: These include cast aluminium components, such front and rear knuckle, with 80 percent secondary material content, and cast aluminium wheel rims with 70 percent secondary aluminium.The housing for the rear electric motor, produced at BMW Plant Landshut, comprises up to two-thirds secondary aluminium. A portion of the energy used in production comes from renewable sources.
In the Gen6 battery cells of the BMW i3 high‑voltage battery, secondary materials are partially used for cobalt, lithium and nickel. Energy from renewable sources is used in manufacturing the anode and cathode materials, as well as for cell production. In comparison to the previous model’s Gen5 cell, CO₂e emissions were reduced by approx. 33 percent per watt hour.
Further examples of the innovative use of engineering and secondary materials include the engine compartment cover and the storage compartment under the BMW i3's bonnet. The starting material for these consists of 30 percent recycled maritime plastic – post-consumer material from used fishing nets and ropes – while the base material for the yarn used in the textiles for the headliner, A-pillar and parcel shelf consists entirely of recycled material.

Enhanced efficiency during use phase.
With the EfficientDynamics technology package, vehicle efficiency is optimised across all subsystems during the use phase.
This encompasses aerodynamics, lightweight construction, rolling resistance and overall energy management, for example. Efficientynamics has been employed by the BMW Group since 2007, across all drive technologies.

BMW Group Plant Munich undergoes extensive modernisation.
BMW Group Plant Munich is the BMW Group’s main plant.For more than a century, the plant has been producing premium mobility in Munich’s Milbertshofen district. Over the past four years, the site has been completely modernised: In addition to a new body shop, a state-of-the-art vehicle assembly was also built, including logistics areas. The new facilities are now in the final stages of construction. Production of the new BMW i3 will get underway here in 2026. Just one year later, the Munich location will transition its production portfolio to exclusively fully-electric vehicles for the Neue Klasse. As the BMW Group’s oldest automobile production site, the plant sources 100 percent of its external electricity requirements from renewable energy.

In line with BMW Group’s sustainable development goals.
The BMW Group’s commitment to the Paris Climate Agreement and to reaching “net zero” no later than 2050 is an integral part of its holistic 360° approach to sustainability, which is anchored in its corporate strategy. The company has set itself ambitious science-based CO₂e targets for the coming years. The BMW Group intends to reduce its CO₂e emissions by a total of at least 40 million tonnes from 2019 levels by 2030.

Transparency through Product Carbon Footprint .
The BMW Group has published its vehicles’ Product Carbon Footprint, as validated by the German Technical Inspection Association (TÜV), for many years in the so-called Vehicle Footprint. This report is publicly available here for all drive trains of the new BMW 3 Series from the Start of Production and can also be accessed in the My BMW app. In this way, the BMW Group creates transparency around the percentage of secondary materials and CO₂e emissions across the vehicles’ entire lifecycle.

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Munich. The BMW Group, together with its partners, has won the globally renowned JEC Composites Innovation Award for series-production exterior components in automobiles. The award was presented at the JEC World Premiere in Paris and recognizes innovations in the development of sustainable materials for the automotive industry.

Innovation and sustainability in automotive engineering.

In June of 2025, the BMW Group first announced the use of natural composites made from flax fibre in the design of series-production vehicles. The award in the "Automotive & Road Transportation Parts" category recognizes BMW Group’s successful integration of these innovative materials. BMW Group’s decision to use natural fibre composites for visible components in series-production vehicles is the most comprehensive application within the industry to date.

Collaboration enables technological breakthrough.

The innovative use of fibre composites is the result of years of research and development work and intensive cooperation with partners Bcomp Ltd., Cobra Advanced Composites Co. Ltd. and PPG Wörwag Coatings GmbH & Co. KG. Together, the consortium succeeded in overcoming a major technical challenge: ensuring the natural fibre composites developed would meet the complex requirements for series production required across the structure of the vehicle, including the high quality needed for the roof panel.

Contribution to CO₂e reduction and lightweight construction.

The use of natural fibres helps to reduce the CO₂e footprint of future vehicle models and has an impact on lightweight construction goals. Material tests show that superior exterior and interior components can be manufactured from these natural fibres.

A concrete example is the use of natural flax fibre composites instead of carbon fibre composites in the roof panels of future models. Replacing carbon roof panel with flax fibre panels can achieve a reduction in CO₂e emissions of around 40% during production plus addition end-of-life considerations.

Collaboration as a success factor.

The development of innovative natural flax fibre composites is the result of successful and intensive collaboration with internal and external partners. Cross-departmental and cross-company cooperation has led to new and innovative solutions in materials and manufacturing processes. Through BMW Group’s use of interdisciplinary expertise, it has been possible to develop forward-looking products and consistently promote sustainability in automotive engineering.

Dr. Herbert Negele, Head of Materials Development and Lightweight Construction, emphasized the importance of BMW Group’s collaborative approach: "At BMW Group, we are committed to thinking and acting responsibly. This premise requires the continuous development of our materials towards sustainability, while continuing to meet the high demands of functionality, lightweight construction and design. The JEC Award confirms our approach and motivates everyone involved in the project to continue along this path.”

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Munich, 2 December 2025. The BMW Group has defined a new 2035 milestone for cutting CO₂e emissions on the road to net zero. The company aims to reduce its CO₂e emissions by at least 60 million metric tons compared to 2019 levels, an additional reduction of approximately 20 million tons of CO₂e beyond the existing 2030 target.

In doing so, the BMW Group is pursuing a comprehensive decarbonization strategy along the entire life cycle, with the goal of achieving net zero by 2050 at the latest. This represents a firm commitment to the goals set out in the Paris Agreement. To date, the target has been to cut at least 40 million metric tons of CO₂e across the entire life cycle (scopes 1, 2 and 3) by 2030 compared to 2019 levels. The new 2035 milestone is a logical next step on this road toward advancing decarbonization. At the same time, the climate impact of the BMW Group’s business model will also be drastically reduced. By 2035, each euro generated will see less than half as much CO₂e emitted compared to 2019.

The key measures for achieving these results include the increasing use of renewable energies in production and the supply chain, the increased utilization of secondary raw materials, efficiency improvements in the use phase, as well as product and process innovations. The latter are being implemented across all drive variants as part of the BMW Group’s technology-neutral approach. In addition, an increasing proportion of the vehicle fleet will continue to be electrified.

Decarbonization along the entire life cycle

The BMW Group has intentionally set itself the additional 2035 milestone to consistently advance its decarbonization strategy. Global customer demand for electric vehicles alone will not be sufficient to achieve the CO₂e targets set for 2030 and 2035. The comprehensive approach to reducing CO₂e emissions therefore spans the entire vehicle life cycle, irrespective of the drive variant.

In the supply chain, which is increasingly relevant in terms of CO₂e emissions, especially for electric models, the company focuses on expanding the use of secondary raw materials and renewable energies. The specific priorities are highly CO₂e-emitting components such as high-voltage batteries, aluminum, and steel. In addition, the company will be implementing product and process innovations, such as in the BMW Group’s sixth generation (Gen6) of battery technology.

The BMW Group also applies high standards in production: for example, since 2020, all electricity sourced from external suppliers for all plants worldwide has come exclusively from renewable sources. The BMW Group also works continuously on replacing fossil fuels. The new iX3 plant in Debrecen, Hungary, is the BMW Group’s first car factory to produce vehicles without any fossil fuels such as oil and gas in standard operation.

To lower CO₂e emissions during the use phase, the BMW Group is implementing additional efficiency measures such as BMW EfficientDynamics, in addition to electrifying its vehicle fleet. As a result, efficiency potential in all vehicle subsystems, such as the drive system, tires, and aerodynamics, is consistently identified and implemented, regardless of the drive technology. The new BMW iX3, for instance, uses up to 20% less energy (WLTP combined) than its predecessor.

Reaching the new milestone will also depend on a variety of external factors, such as the transformation of the steel industry in favor of more CO₂e-reduced steel, the expansion of the charging infrastructure, progress in the circular economy, and the advancement of battery cell technologies. This is why the BMW Group continues to pursue a number of strategic initiatives, such as the ongoing expansion of in-house expertise in state-of-the-art battery cell centers of excellence and innovative circular economy projects.

Further  information:

Sustainability in the iX3

Battery Competence Center

Recycling and Dismantling Centre 

Bitte wenden Sie sich bei Rückfragen an:

BMW Group, Presse- und Öffentlichkeitsarbeit

Isabel Richter

Teamlead Sustainability Communication BMW Group

Telefon: +49-151-601-53189

E-Mail: Isabel.Richter@bmwgroup.com

Internet: https://newsroom.bmwgroup.com/global/en

E-Mail: presse@bmwgroup.com

The BMW Group

With its four brands BMW, MINI, Rolls-Royce and BMW Motorrad, the BMW Group is the world’s leading premium manufacturer of automobiles and motorcycles and also provides premium financial services. The BMW Group production network comprises over 30 production sites worldwide; the company has a global sales network in more than 140 countries.

In 2024, the BMW Group sold over 2.45 million passenger vehicles and more than 210,000 motorcycles worldwide. The profit before tax in the financial year 2024 was € 11.0 billion on revenues amounting to € 142.4 billion. As of 31 December 2024, the BMW Group had a workforce of 159,104 employees.

The economic success of the BMW Group has always been based on long-term thinking and responsible action. Sustainability is a key element of the BMW Group’s corporate strategy and covers all products from the supply chain and production to the end of their useful life.

www.bmwgroup.com

LinkedIn: http://www.linkedin.com/company/bmw-group/

YouTube: https://www.youtube.com/bmwgroup

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

Facebook: https://www.facebook.com/bmwgroup

X: https://www.x.com/bmwgroup

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Munich/Parsdorf. With the publication of its Environmental Impact Statement 2024, all BMW Group operations in Parsdorf are now part of the European environmental register, EMAS. In addition to the BMW Group Cell Manufacturing Competence Centre (CMCC) and test-parts logistics, the pilot plant for high-voltage batteries in Parsdorf has been included in the environmental impact statement and EMAS registration for the first time. EMAS stands for the “Eco-Management and Audit Scheme”, which claims to be the most stringent environmental management system in the world. “We are very pleased with the EMAS registration of all our operations in Parsdorf, which underlines that our processes operate at a very high level – both economically and environmentally,” says Hansjörg Schilp, director of the CMCC and pilot plant for high-voltage batteries in Parsdorf. “The entire team has done an outstanding job.”

EMAS: Strict requirements and high environmental standards

To be listed in the EMAS Register, companies must fulfil strict requirements and adhere to rigorous environmental standards. EMAS is a globally recognised framework that enables organisations to manage and continuously improve their environmental impact. A key element of the EMAS environmental management system is the international environmental management standard ISO 14001. EMAS also focuses on measurable improvements, transparency and legal certainty. Auditing aims to support companies in continuously improving their environmental performance – for example, by using energy and material more efficiently and reducing emissions, wastewater and waste from their sites. Beyond these direct environmental impacts, EMAS also addresses and evaluates indirect aspects, including the sustainability of products, procurement and supply chains, contractor practices and the environmental impact of employees commuting to work. (Source: https://www.umweltbundesamt.de/themen/wirtschaft-konsum/wirtschaft-umwelt/umwelt-energiemanagement/emas-umweltmanagement-guetesiegel-der-europaeischen#systematisches-umweltmanagement-mit-emas)

Efficient operations and concepts for the circular economy

The validated environmental impact statement and the resulting inclusion in the EMAS Register by the Chamber of Commerce and Industry (IHK) for Munich and Upper Bavaria underscore the rigorous environmental standards upheld by the BMW Group in Parsdorf. Battery cell production at the CMCC, one of the three Parsdorf facilities, is powered entirely by electricity from 100% renewable energy sources. Hot water for process ventilation is generated using waste heat recovered from various primary processes, and all three Parsdorf facilities utilise heat pumps in their operations. “On our pilot lines for battery cells and high-voltage batteries, we are focusing on reducing the use of critical raw materials and energy, avoiding solvents and developing innovative circular economy approaches,” explains Schilp. Raw materials represent a significant cost factor for battery cells and high-voltage batteries. Efficient and responsible use of these resources is therefore necessary and also makes economic sense. The BMW Group is gaining valuable insights in this area in Parsdorf. Residual materials from the production process are collected and, wherever technically feasible, reintegrated into the value-creation cycle at the BMW Group’s Competence Centres through direct recycling. This innovative procedure enables residual materials from battery cell production, as well as whole battery cells, to be mechanically dismantled into their components.

Transparent reporting: Environmental impact statement now online

The environmental impact statement for the BMW Group’s Parsdorf  operations (CMCC, pilot plant for high-voltage batteries and test-parts logistics) has been independently reviewed by TÜV SÜD Umweltgutachter GmbH and is now available online at: www.bmwgroup-werke.com/produktionskompetenz/de.html

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

Cell manufacturing at the CMCC in Parsdorf 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 in the jargon as calendered electrodes, are coiled 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.

Parsdorf pioneers: How the BMW Group builds Gen6 high-voltage batteries

Parsdorf is also home to the BMW Group’s largest pilot plant for Gen6 high-voltage batteries, where production processes are developed and tested before large-scale production begins at the series plants in Debrecen (Hungary), Irlbach-Straßkirchen (Lower Bavaria), Shenyang (China), San Luis Potosí (Mexico) and Woodruff (USA). More than 350 employees have been building initial high-voltage battery prototypes here since 2023. In the meantime, these batteries have also been delivered to the vehicle plant in Debrecen, Hungary, where they were installed in test vehicles for the Neue Klasse. For series production, 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 coolers. This step ensures optimal insulation and cooling of the cells. The cell clusters and cell contact system are then laser-cleaned and welded with pinpoint precision. The 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.