BMW to launch series production of iX5 batteries in December

The new BMW plant in Woodruff, South Carolina, USA, will begin series production of high-voltage batteries for the upcoming iX5 eSUV in December. The battery assembly plant deploys AI, digital twins, and the cell-to-pack principle. The BMW Group is preparing to launch series production of its sixth-generation (Gen6) batteries for electric vehicles – starting with high-voltage batteries for the all-electric BMW iX5, which will begin at its Woodruff plant this December. The facility is a cornerstone for the North American market and was built near the Spartanburg vehicle plant, where the iX5 will be manufactured, in line with the ‘Local for Local’ principle. From there, the vehicle will also be exported to Europe. To achieve this, the carmaker has implemented cutting-edge processes. The new cylindrical cells in the 46120 format from battery cell manufacturer AESC are integrated directly into the battery pack using the ‘Cell-to-Pack’ method. All production steps are monitored seamlessly in real time. Specially developed AI assistants process data alongside more than 300 employees and 250 robots to ensure zero-defect production. Even during the planning and ramp-up phases, BMW consistently relied on digital tools. Digital twins and virtual reality applications facilitated factory planning, while employees completed a specially developed VR training programme. This allowed them to practice real-world processes and equipment operations in a highly detailed virtual environment. “Plant Woodruff plays a key role in the ramp-up of electromobility in the US,” said BMW Production Director Raymond Wittmann. “With our Gen6 high-voltage battery, we’re not only taking a major technological leap – we are also setting new standards in production. In Woodruff, we are combining cutting-edge processes, artificial intelligence and the expertise of our employees to create a production facility designed for the highest quality.” Technologically, the system is based on an 800-volt architecture. The BMW iX5 60 xDrive offers a usable net energy content of 144kWh in the USA and 141kWh in Europe. In terms of sustainability, the Gen6 battery cell reduces CO₂e emissions by around 28 per cent compared to the previous generation. This reduction is achieved through the use of secondary materials for cobalt, lithium, and nickel, as well as green electricity in cell production. The Woodruff plant itself operates entirely without fossil fuels during normal operations, while its material handling equipment is powered by hydrogen. The foundation for the project was laid in June 2023 with the groundbreaking ceremony for the Woodruff plant. Construction commenced in September 2023, followed by the installation of equipment in autumn 2024. Pre-series test runs began in summer 2025. The investments in Woodruff are part of a comprehensive US strategy, in which BMW invested approximately $1.7 billion in electromobility in the Spartanburg region, including partnerships with local cell suppliers such as AESC. bmwgroup.com