In December 2026, BMW Group Plant Woodruff in South Carolina will begin series production of high-voltage batteries for the new fully electric BMW iX5. The facility features advanced manufacturing technologies, including AI-supported processes, digital twins and virtual reality applications, to achieve real-time monitoring and comprehensive documentation of each production step.
The Gen6 high-voltage battery employs a “cell-to-pack” design, integrating cylindrical round cells directly into the module. Onsite AI assistants analyze inline data alongside input from more than 300 employees and 250 robots to support zero-defect assembly and boost Overall Equipment Effectiveness. Digital twins of production lines and VR training enable staff to rehearse operations under realistic conditions before handling physical equipment.
Construction of Plant Woodruff began in September 2023 following a June 2023 groundbreaking, with manufacturing equipment installation starting in September 2024. Preparations for battery assembly commenced in mid-2025, and pre-series batteries have been produced since that summer. The site is part of BMW’s “local for local” strategy, which locates battery plants close to vehicle assembly facilities. Other Gen6 battery production sites include Irlbach-Straßkirchen (Germany), Shenyang (China), San Luis Potosí (Mexico) and Debrecen (Hungary), where series production has been underway since October 2025.
The Gen6 cells contain a higher proportion of recycled cobalt, lithium and nickel, and renewable energy is used in anode, cathode and cell production. Compared with the previous generation, CO₂e emissions are reduced by around 28 percent per watt-hour. Normal operations at Woodruff run without fossil fuels, and industrial trucks are powered by hydrogen.
Battery assembly steps cover receipt and inspection of cells, clustering and integration with cooling elements, laser-guided welding of cell contacts, a precision foaming process for structural support, and final enclosure sealing. The Energy Master control unit is installed last, followed by a 100 percent end-of-line test. Completed batteries are then shipped 15 miles to BMW Group Plant Spartanburg for vehicle integration.
The BMW iX5 will feature sixth-generation eDrive technology with an 800-volt architecture and up to 144 kWh of net energy content in the U.S. configuration, making it the brand’s largest high-voltage battery to date. Dual e-motors and electric all-wheel drive will deliver propulsion across both axles.
Source: BMW Group Press Release (https://www.press.bmwgroup.com/global/article/detail/T0459241EN/first-glimpse-into-production:-bmw-group-plant-woodruff-assembles-high-voltage-batteries-for-the-new-bmw-ix5?language=en)
