BMW Plant Woodruff: Battery Production for the BMW iX5 Takes Concrete Shape

Electromobility BMW Plant Woodruff: Battery Production for the BMW iX5 Takes Concrete Shape

2026-07-28 From Stefanie Eckardt| Translated by AI 3 min Reading Time

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In December of this year, the new BMW Plant Woodruff will begin series production of the high-voltage batteries installed in the new iX5. As part of its world premiere, the company provided insights into the manufacturing process. With AI-supported production processes, digital twins, and virtual reality applications, they aim to set new standards here.

Series production is ready to begin: Starting December 2026, high-voltage batteries for the iX5 will be manufactured at the BMW Plant Woodruff.(Image: BMW) — Series production is ready to begin: Starting December 2026, high-voltage batteries for the iX5 will be manufactured at the BMW Plant Woodruff.
(Image: BMW)

"The Woodruff plant is a crucial pillar for scaling up electromobility in the USA," emphasizes Raymond Wittmann, BMW’s Head of Production. "With our Gen6 high-voltage battery, we are not only making a significant technological leap but also setting new standards in production. In Woodruff, we combine state-of-the-art processes, artificial intelligence, and the expertise of our employees to create efficient manufacturing consistently focused on the highest quality."

For the in-house developed Gen6 high-voltage battery, the automaker has created intelligent and efficient production processes. The new cylindrical cells are integrated directly into the battery using the "cell-to-pack" principle. All production steps are seamlessly monitored inline and comprehensively documented in real-time. Specially developed AI assistants and agents analyze this data and, together with more than 300 employees and 250 robots at the Woodruff plant, ensure zero-defect battery production. At the same time, the use of AI is intended to improve overall equipment effectiveness (OEE) in manufacturing. Long before commissioning, digital twins of production and virtual reality applications facilitated planning and qualification.

Train Employees through VR Training

At the Woodruff plant, all manufacturing employees complete an on-site developed VR training. In a virtual factory, they can realistically practice the processes of actual production. The virtual space replicates the plant's production lines accurately and in detail. All that is needed is a VR headset and a PC. Through this training, process understanding and operational safety are developed even before employees work with the actual production systems for the first time.

Sustainability

The Gen6 battery cells for the new vehicle incorporate a high proportion of secondary materials for cobalt, lithium, and nickel. Renewable energy is also used in the production of the anode and cathode materials as well as in cell manufacturing. Compared to the Gen5 cell of the BMW iX, CO₂e emissions per watt-hour have been reduced by approximately 28 percent. The Woodruff plant operates completely without fossil fuels under normal conditions. The material handling vehicles on-site are powered by hydrogen.

Local-For-Local Strategy

The assembly of Gen6 high-voltage batteries takes place in five new production facilities that BMW has established close to its vehicle plants following the "Local for Local" principle. In addition to Woodruff, assembly plants for high-voltage batteries are being set up in Irlbach-Straßkirchen (Lower Bavaria), Shenyang (China), and San Luis Potosí (Mexico). In Debrecen, Hungary, high-voltage batteries have been mass-produced since October 2025. The "Local for Local" approach aims to strengthen regional infrastructures as well as existing locations and secure jobs. The global production network for high-voltage batteries benefits from the close collaboration between the German pilot plants and worldwide series production facilities.

iX5 60 xDrive Features the Largest HV Battery of any BMW Model

The fully electric BMW iX5 relies on the sixth generation of BMW eDrive technology with cylindrical cells and 800-volt technology. With a usable energy content of 144 kWh in the US and 141 kWh in the EU (net), the iX5 60 xDrive features the largest high-voltage battery of any BMW model to date. Propulsion is provided by an electric motor on both the front and rear axles and the electric xDrive all-wheel drive.

Robin Zeng, Chairman and CEO of CATL, is driving forward the development of modern battery technologies. (Image:CATL)

The concept of the blade battery. (Image:BYD Europe B.V.)

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