BMW GROUP OPENS HIGH-VOLTAGE BATTERY ASSEMBLY PLANT IN WOODRUFF

The BMW Group officially opened its new Plant Woodruff in South Carolina today, marking the start of series production. The facility will supply sixth-generation (Gen6) high-voltage batteries for installation in the new BMW iX5 and future electric vehicles at BMW Group Plant Spartanburg, which is located just 15 miles away. The iX5 is BMW’s first fully electric model to be assembled in the United States.

Following Debrecen (Hungary), Irlbach-Straßkirchen (Germany) and Shenyang (China), Woodruff is the fourth site in the BMW Group production network to begin series production of Gen6 high-voltage batteries. With AI-supported production processes, digital twins and virtual reality applications, the new plant is setting industry standards for the assembly of high-voltage batteries.

Local for local: Five Gen6 high-voltage battery sites

Assembly of the Gen6 high-voltage batteries takes place at five new facilities, which the BMW Group built close to its vehicle plants, in line with its “local for local” principle. In addition to Woodruff, four more state-of-the-art high-voltage battery assembly plants have also been built: Debrecen (Hungary), Irlbach-Straßkirchen (Germany), Shenyang (China) and San Luis Potosí (Mexico). Gen6 high-voltage batteries have been series produced in Debrecen, Hungary, since October 2025. Plants Irlbach-Straßkirchen and Shenyang began series production in October 2026. Plant San Luis Potosí will follow in 2027.

Intelligent production for maximum quality

The BMW Group has established state-of-the-art, intelligent and efficient production processes for its in-house developed Gen6 high-voltage battery. The new cylindrical round cells are integrated directly into the high-voltage battery, based on the “cell-to-pack” principle. All production steps are continuously monitored inline and comprehensively documented in real time. AI assistants and agents developed in-house analyse this data and, together with more than 300 employees and 250 robots at Plant Woodruff, help ensure zero-defect battery production. At the same time, the extensive use of artificial intelligence enhances Overall Equipment Effectiveness (OEE) in production. Well before commissioning, digital twins of production and virtual reality applications support planning and employee training.

Training in a virtual factory

All production staff at Plant Woodruff complete a VR training programme developed on site. Within a virtual factory, they can practise real manufacturing operations under realistic conditions. This virtual environment replicates the plant’s production lines in meticulous detail. The training helps employees develop an understanding of relevant processes and builds confidence in operating the equipment before they use it for the first time in actual production.

From start of construction to series production in just over three years

Following the official groundbreaking in June 2023, construction of the new plant began in September 2023. Just one year later, in September 2024, while construction was still under way, installation of the manufacturing equipment began, with the first test and pre-series batteries rolling off the assembly line in summer 2025.

Gen6 battery cells with reduced carbon footprint

The Gen6 battery cells for the BMW iX5 include a high proportion of secondary materials in their cobalt, lithium and nickel content. Renewable energy is also used in the production of anode and cathode materials, as well as in cell manufacturing. Compared with the Gen5 cell used in the BMW iX, CO₂e emissions have been reduced by around 28 percent per watt-hour. Plant Woodruff does not use any fossil fuels during normal operations, while the site’s industrial trucks are powered by hydrogen.

How the BMW Group builds its Gen6 high-voltage batteries

The BMW Group sources battery cells for its high-voltage batteries from leading cell manufacturers. The highest technical standards apply. Upon receipt of goods, additional measurements – such as voltage checks – are carried out. This is followed by so-called cell clustering, where the battery cells are connected to coolers. This step ensures optimal insulation and cooling of the cells. The cell clusters and cell contact system are then laser-cleaned and welded with pinpoint precision. The in-line inspection continuously monitors each weld seam in real time, while an innovative foaming process ensures that all elements are protected as a mechanical unit. The hardened foam guarantees the safety, stability and durability of the high-voltage battery. The housing is then closed, sealed and riveted. In the final assembly step, the Energy Master – the central control unit – is installed onto the high-voltage battery. Finally, each high-voltage battery undergoes a 100% end-of-line inspection. From Woodruff, the high-voltage batteries are transported to Plant Spartanburg, located just 15 miles away.

Questions and Answers

Why is the BMW Group building high-voltage batteries in Woodruff?

The site’s proximity to BMW Group Plant Spartanburg is a major advantage. The Gen6 high-voltage batteries assembled in Woodruff are transported only 15 miles to Spartanburg, where they are installed in the new BMW iX5, the first fully electric vehicle assembled in the United States. In this way, the BMW Group is implementing its “local for local” principle and closely integrating battery and vehicle production in South Carolina.

Will battery cells also be produced in Woodruff?

No. In Woodruff, supplied battery cells are assembled into Gen6 high-voltage batteries. The BMW Group sources the battery cells from leading cell manufacturers, which manufacture them to the company's specifications. At the plant, the cells are inspected and then integrated directly into the high-voltage battery, based on the “cell-to-pack” principle. The BMW Group maintains its product and process expertise for battery cells through its own competence centres in Bavaria.

What role do AI and automation play in production?

All production steps are monitored inline and documented in real time. AI assistants and agents developed in-house analyse the data generated in this way, support production processes and ensure quality. More than 300 employees and around 250 robots work together at Plant Woodruff. Each high-voltage battery also undergoes a 100-percent end-of-line inspection.

What are the advantages of Gen6 battery technology?

The new round cells offer more than 20 percent higher energy density than the previous cell generation. Charging times are reduced by up to 30 percent and range is 30 percent higher – even more in certain models.

Over what period did the BMW Group build Plant Woodruff?

Following the groundbreaking in June 2023, construction of the plant began in September 2023. Just one year later, while construction was still under way, installation of the manufacturing equipment commenced. Production of the first test and pre-series batteries began in summer 2025. The official inauguration marks the start of series production. This means just over three years elapsed between the start of construction and the start of series production.