BMW Group will begin series production of its sixth-generation (Gen6) high-voltage batteries at its new Woodruff, South Carolina, plant in December, supporting the launch of the all-electric BMW iX5 for North American and export markets.
The battery assembly facility will supply packs for the iX5, which will be manufactured at BMW’s nearby Spartanburg plant before being sold in North America and exported to Europe. The project forms part of the automaker’s “Local for Local” manufacturing strategy, which aims to locate battery production close to vehicle assembly.
AI and Cell-to-Pack Technology Drive Production
The Woodruff plant will manufacture BMW’s Gen6 battery packs using cylindrical 46120 battery cells supplied by AESC.
The cells will be integrated directly into battery packs using the cell-to-pack manufacturing method, eliminating intermediate modules to improve energy density and production efficiency.
BMW said the production process is monitored in real time using artificial intelligence and digital manufacturing systems. More than 300 employees and 250 robots will support battery assembly, while AI assistants analyze production data to help maintain quality standards.
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The company also used digital twins and virtual reality throughout factory planning and employee training. Workers completed VR-based training programs before production, allowing them to familiarize themselves with equipment and manufacturing processes in a virtual environment.
Production Director Raymond Wittmann said the facility represents an important milestone for BMW’s electric vehicle expansion in the United States.
“Plant Woodruff plays a key role in the ramp-up of electromobility in the US. With our Gen6 high-voltage battery, we’re not only taking a major technological leap – we are also setting new standards in production.”
He added that the company is combining advanced manufacturing technologies with employee expertise to support high-quality battery production.
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“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.”
800-Volt Architecture and Sustainability
The Gen6 battery platform is built around an 800-volt electrical architecture.
BMW said the U.S.-specification iX5 60 xDrive will feature 144 kWh of usable battery capacity, while the European version will offer 141 kWh.
According to the automaker, the new battery generation reduces lifecycle carbon dioxide equivalent (CO₂e) emissions by approximately 28% compared with the previous generation through the use of recycled cobalt, lithium and nickel, as well as renewable electricity during battery cell production.
BMW added that the Woodruff facility operates without fossil fuels during normal production, while its material handling equipment is powered by hydrogen.
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Construction of the Woodruff plant began after the project’s groundbreaking in June 2023, with equipment installation starting in late 2024 and pre-series production trials commencing during the summer of 2025.
The investment forms part of BMW’s broader $1.7 billion electrification strategy in South Carolina, which also includes partnerships with local battery suppliers such as AESC.