AESC has officially started mass production of its new 46120 large-format cylindrical battery cells, marking an important milestone for BMW Group’s next-generation electric vehicle program. The advanced battery cells will power multiple models built on BMW’s Neue Klasse platform, with the all-electric BMW iX5 confirmed as the first announced vehicle to use the technology.
The production launch represents years of research and development aimed at improving battery performance, manufacturing quality, and scalability as automakers accelerate the transition to electric mobility.
BMW iX5 Leads the Rollout
The first announced production model to feature AESC’s new 46120 battery cells is the all-electric BMW iX5, which is expected to reach the market in late 2026 or early 2027.
Although the iX5 is based on BMW’s CLAR architecture rather than the dedicated Neue Klasse platform, it will introduce the company’s sixth-generation eDrive battery technology. The electric SUV is expected to feature a 141-kWh (net) battery pack and an 800-volt electrical architecture, delivering faster charging, improved efficiency, and longer driving range compared with BMW’s current generation of prismatic battery cells.
BMW plans to expand the use of the new cylindrical cells across additional Neue Klasse models as its next-generation EV lineup grows.
Larger Cylindrical Cells Deliver Higher Energy Density
The new battery cell measures 46 mm in diameter and 120 mm in height, making it AESC’s latest advancement in large-format cylindrical battery technology.
Compared with previous battery formats, the 46120 cell increases usable energy per cell by nearly 30%. The larger format also reduces the number of individual cells and components required inside the battery pack, simplifying pack construction while improving overall system integration and offering greater flexibility for vehicle packaging.
The battery chemistry combines a high-nickel cathode with a silicon-doped anode, enabling an energy density of up to 310 Wh/kg. According to AESC, the combination of improved materials, optimized structural design, and enhanced thermal management is intended to increase performance while supporting long-term durability and system-level safety.
These improvements are particularly beneficial for larger premium electric vehicles such as SUVs, where maximizing range without significantly increasing battery size or weight is critical.
Advanced Manufacturing Focuses on Precision and Quality
To support large-scale production, AESC has equipped its manufacturing lines with extensive quality-control systems.
More than 1,000 CCD vision-inspection checkpoints monitor the production process, while every battery cell undergoes 100% X-ray inspection to detect potential foreign objects or manufacturing defects before leaving the factory.
Production also utilizes a magnetic-levitation material handling system alongside high-precision manufacturing equipment capable of maintaining dimensional tolerances within 0.01 mm, helping ensure consistent battery quality at scale.
David Wan, Global CEO of AESC, highlighted the significance of the production launch:
“Years of R&D and manufacturing expertise have enabled the mass production and global rollout of our 46120 cells.”
He added that leading automakers have demonstrated confidence in AESC’s manufacturing capabilities, product quality, and ability to supply battery cells at global scale.
Global Manufacturing Network Supports Growing EV Demand
AESC says mass production has begun at its advanced manufacturing facilities, although the company has not disclosed which specific plant is producing the new 46120 cells.
The battery manufacturer currently operates or is building production facilities across China, Japan, the United States, the United Kingdom, France, and Spain, allowing it to supply automakers through localized manufacturing and diversified supply chains.
One unanswered question is where the battery cells for the BMW iX5 will ultimately be produced. AESC had previously announced plans to build a battery plant in Florence County, South Carolina, to support BMW’s U.S. operations after securing a major supply agreement in 2022. However, work on the project was paused in mid-2025, leaving uncertainty about whether production for the iX5 will come from that facility or another AESC manufacturing site.
Supporting BMW’s Next Generation of Electric Vehicles
The start of 46120 battery production represents another key step toward BMW’s next generation of electric vehicles. By combining higher energy density, simplified battery pack design, improved safety, and advanced manufacturing processes, the new cylindrical cells are expected to play a central role in the automaker’s upcoming Neue Klasse lineup.
As BMW prepares to launch the all-electric iX5 and additional Neue Klasse models over the next several years, AESC’s latest battery technology is set to become an important building block in delivering longer range, faster charging, and improved overall efficiency for future BMW EVs.
