At the recent Tech Days event in Landshut, Germany, BMW Group offered a detailed look into the development and production of its sixth-generation high-voltage battery and electric drive systems, set to power the forthcoming Neue Klasse series. Series production of these Gen6 drive units is slated to commence at BMW’s Steyr plant in Upper Austria by mid-2025.
Pre-series production began in September 2024, with initial units undergoing rigorous testing. Some of these pre-series motors are already integrated into Neue Klasse test vehicles produced at BMW’s Debrecen facility in Hungary. The next-generation iX3, anticipated to be the first model based on the Neue Klasse platform, is scheduled to enter series production later this year.
Building upon the efficiency of its fifth-generation electric drives, currently utilized across models from the iX1 to the i7, BMW describes the Gen6 technology as a “technological leap forward.” This advancement encompasses both the drive systems and the battery components.
The Gen6 electric drives maintain the use of current-excited synchronous machines (SSM), where the rotor’s magnetic field is generated by windings supplied with direct current, eliminating the need for permanent magnets. This design allows for optimal adjustment of the rotor’s magnetic field strength based on load conditions, enhancing efficiency and consistent power output at high rotational speeds. Additionally, the SSM has been refined to align with the new 800-volt architecture, featuring redesigned oil and water cooling systems and a lighter, more rigid housing.
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In a strategic shift, BMW plans to employ asynchronous machines (ASM) for the front axle in all-wheel-drive models, while the rear axle will continue with the SSM setup. ASMs, which generate the rotor’s magnetic field through induction from the stator, are generally more compact and cost-effective. BMW anticipates that this combination will lead to a 40% reduction in energy losses, a 20% decrease in costs, and a 10% weight reduction when comparing future all-wheel-drive models to current Gen5 xDrive models. Overall vehicle efficiency in the Neue Klasse is projected to improve by 20%.
“By combining different types of electric motor, the BMW Group’s technology-open approach is therefore clearly in evidence within the field of electric mobility,” the company stated. Future offerings will include models equipped with one to four electric motors, catering to diverse customer preferences and requirements.
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The Gen6 battery system introduces significant changes, transitioning from a 400-volt to an 800-volt architecture and shifting from prismatic cells to large-format cylindrical cells with a 46-millimeter diameter. This new cell design offers a 20% increase in energy density compared to previous prismatic cells. The battery pack adopts a module-free construction, serving as a structural component within the vehicle’s body—a concept referred to as “pack-to-open-body.” This integration allows for a higher number of cells within the same space, enhancing energy density at the pack level. BMW also claims improvements of up to 30% in both charging speed and vehicle range, with certain models achieving even higher figures.
While electric drives and inverters, featuring in-house developed silicon carbide semiconductors, will be manufactured at the Steyr plant and distributed to various production facilities, BMW is adopting a “local for local” strategy for battery production. Battery assembly plants are being established in proximity to vehicle manufacturing sites, including locations in Irlbach-Straßkirchen (Germany), Debrecen (Hungary), Shenyang (China), San Luis Potosí (Mexico), and Woodruff near Spartanburg (USA). This approach aims to enhance supply chain resilience and reduce logistical complexities.
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To meet the demand for Gen6 batteries, BMW has secured agreements with partners to construct five battery cell factories across Europe, China, and the USA. This expansion aligns with BMW’s commitment to sustainable and efficient production practices.
A pivotal component of the new electric drive system is the “BMW Energy Master,” an energy management unit developed entirely in-house. This system oversees the high-voltage and low-voltage power supply, ensuring safe and intelligent battery operation, thereby enhancing durability. It also manages power distribution to the electric motors and facilitates communication with the vehicle’s central drive computer, known as the “Heart of Joy.” The Energy Master is currently in pre-series production in Landshut, with full-scale production expected to commence in August 2025. The facility anticipates employing approximately 200 individuals at launch, expanding to around 700 as production scales up.
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Joachim Post, BMW Board Member for Purchasing and Supplier Network, emphasized the company’s strategic direction: “For the BMW Group, electric mobility is the future and a key area of growth. We are leading the way with this drivetrain technology. At the same time, we are deliberately taking a technology-open approach, recognizing that mobility needs vary between different regions of the world.”
Gallery: BMW Sixth Drive Generation
