What is Special About BMW's Next-Gen EV Batteries?

As the automotive industry moves toward a fully-electric era, the technical architecture of the battery becomes the primary differentiator for vehicle performance.

To support the 2025 launch of the "Neue Klasse" – a new generation of vehicles designed to usher in a fully electric era – BMW is developing a dedicated high-voltage battery assembly plant in Irlbach-Straßkirchen, Lower Bavaria.

The plant is needed to supply the vehicle manufacturing plants in Dingolfing, Regensburg and Munich.

The facility focuses on the assembly of the Gen-6 battery, a move away from former prismatic cell designs.

"Our battery cells have a diameter of 46 mm and we use it in two different heights. One is 95 mm and the other 120 mm," says Dr Markus Fallböhmer, Senior Vice President Battery Production, BMW.

"Compared to the prismatic cells of the former generation, our new cylindrical cells have a 20% increased energy density. We are convinced that we offer the optimum cell and pack to our customers worldwide. The Gen-6 offers a huge step forward in technology."

Strategic location for regional production

BMW’s commitment to Eastern Bavaria is rooted in retaining approximately 30,000 jobs while moving to a net zero future.

With existing factories lacking the required space for a project of this magnitude, BMW chose a 100-hectare industrial plot in Irlbach-Straßkirchen that met strict logistical and environmental criteria: it was flat, required no deforestation and sat outside water protection zones.

"At the end of 2022, we made the decision to start the project in February 2023," explains Sabrina Kugler, Overall Project Manager Plant Construction Irlbach-Straßkirchen.

"We purchased the land after looking at 20 other areas. A referendum took place on 21 September 2023. There was a clear and strong vote from citizens. Yes, BMW should build a new plant here."

Construction began in April 2024, aiming to create 1,600 positions and produce 1,000 batteries per working day.

Cell-to-pack integration and weight reduction

The move to Gen-6 is a rethink of how batteries are integrated into the vehicle. By leaving behind traditional modules, BMW has created a slimmer, more integrated unit.

"With the new cells comes a completely new concept for the high voltage battery," Markus says. "No modules, no struts and a more efficient and flat design, and one concept for our whole fully electric portfolio.

"The energy content of the pack is scalable through the rows of cells. The result is a more compact, slimmer and lighter battery with more energy inside."

This "cell-to-pack" approach allows the battery to be integrated directly into the vehicle's cast structure, saving space and improving aerodynamics.

Advancing towards a fully electric portfolio

BMW’s commitment to the electric transition is reflected in its goal to ensure more than half of its global sales are fully electric before 2030.

"We produce with the zero defect principle, including continuous inline quality inspection," Markus says. "We use digital twins of production with a comprehensive AI database for process optimisation and employee training."

Circular economy and battery cell recycling

Sustainability at the new plant extends beyond the electric drive, encompassing the entire lifecycle of the battery. BMW identifies the high-voltage battery as the most valuable recyclable component of an EV and the company is researching in-house processes to keep raw materials within the value chain.

"The recycling of high voltage batteries at the end of their lifecycle is also coming more into focus," says Markus. "Therefore, we partner with leading recycling companies. Our partners convert the old batteries into high quality metals that can be reintroduced to battery production."

BMW is also developing a Cell Recycling Competence Centre (CRCC) in Lower Bavaria. Markus adds: "Thanks to our direct recycling process, residue from battery cell production and entire battery cells can be mechanically broken down into their valuable components."

Advancing net zero through innovation efficiency

BMW is committed to the Paris Climate Agreement, aiming for net zero across the entire value chain by 2050

The Irlbach-Straßkirchen plant is a statement of intent, using zero-defect principles and AI-driven process optimisation.

"We produce with the zero defect principle, including continuous inline quality inspection," Markus says. "We use digital twins of production with a comprehensive AI database for process optimisation and employee training."

By streamlining the production process – specifically by eliminating cell coating and modules – the company reduces complexity while maintaining high standards.

Markus says: "For the sixth generation of high voltage batteries, we are adding five new production sites following the local for local principle. This means we place them as close as possible to the vehicle plants. The short distances reduce the CO2 footprint in vehicle production."