BMW launches sixth-gen battery production in Shenyang
The BMW Group has begun series production of its Gen6 high-voltage batteries for the Neue Klasse in Shenyang. Following Debrecen and Irlbach-Straßkirchen, the site in northeastern China is the third plant in the company's new battery network. In future, the energy storage systems produced there will power the Neue Klasse models that BMW will manufacture in China for the local market.
Image: BMW
Nowhere is the price competition for EVs as fierce as in China – and it’s well-known that batteries are the most expensive component of an electric car. Manufacturing it close to the vehicle plant thus saves transport routes and inventory costs. This is exactly what BMW is now doing in Shenyang: “The high-voltage battery is a key component of our all-electric vehicles and one of the BMW Group’s most important technologies for the future,” said Production Board Member Dr. Raymond Wittmann. He added: “Production in Shenyang exemplifies our global approach: We manufacture locally, efficiently and close to our markets, in line with uniform global standards and the highest quality.”
Large round cells replace modules
The sixth generation relies on large round cells with a diameter of 4.6 cm, which BMW uses in two heights: 9.5 and 12 cm. Compared to the previous cell generation, energy density increases by more than 20 per cent while charging speed and range even see improvements of up to 30 per cent.
The battery also utilises a novel design. Previously, the cells were housed in modules, which were then installed in the battery housing in a second step. With the cell-to-pack principle, this intermediate level is eliminated, and the cells are placed directly in the housing. This saves material and weight, and the freed-up space can be filled with additional cells. On top of the battery is the Energy Master, a control unit developed by BMW itself. It combines functions of the power supply and battery management. The latter monitors, among other things, the state of charge and the temperature of the cells.
Battery production methods in Shenyang
In Shenyang, the cells are first inspected and then connected to coolers to form clusters. After laser cleaning, the clusters are welded to the cell contact system, which electrically connects the cells. A foaming process mechanically secures the components. The housing is then closed, sealed, and riveted. Finally, the Energy Master is installed, followed by an end-of-line inspection of each individual battery. Quality control for round cells is particularly complex because a pack consists of a very large number of individual cells, and every weld must hold. BMW therefore monitors the laser weld seams with inspection systems directly on the line in real time and also uses digital twins and AI-supported testing methods.
BMW Group’s largest production site
The conversion of the Shenyang site for the Neue Klasse was formalised in a letter of intent between BMW and Liaoning Province in April 2024. This involved an equivalent of ~€2.5 billion euros. With an annual capacity of 830,000 vehicles as of 2024, Shenyang is the largest production site in the group. It is spread across the Dadong, Lydia, and Tiexi plants. The site is operated by the joint venture BMW Brilliance Automotive. Just before Christmas 2025, the pre-series of the first Neue Klasse model for the Chinese market, the long-wheelbase iX3, began production there. One of BMW’s Chinese partners is the battery manufacturer CATL.
BMW’s production network is also expanding outside China. In the coming months, battery assembly in Woodruff, South Carolina, USA, and in San Luis Potosí, Mexico, is set to begin series production.
The start of battery production in China comes just in time for the long-wheelbase iX3. BMW launched the model for pre-sale at the Chengdu Auto Show in August. Prices range from 269,900 yuan (~€36,100 euros) for the iX3 30L to 339,900 yuan (~€45,400 euros) for the 50L xDrive. According to _CnEVPost_, the first deliveries are planned for November. However, _CarNewsChina_ states that larger volumes will not reach customers until 2027, citing the business portal _36Kr_. BMW sources attribute the long wait to the quality testing of new technologies.