BMW has officially opened its new battery production plant in Irlbach-Straßkirchen, Bavaria, Germany, marking the start of series production of sixth-generation high-voltage batteries for its Neue Klasse electric vehicles. The facility is already supplying BMW Group Plant Munich with batteries for the new BMW i3, with production ramping up faster than initially planned due to strong demand for Neue Klasse models.
Construction of the new facility began in April 2024, and the first pre-series battery was produced in March 2026. Less than two and a half years after construction started, the plant is now operating on a two-shift basis, highlighting BMW’s efforts to expand battery production capacity as demand for electric vehicles grows.
With an investment of approximately €1 billion, the new facility also represents a significant expansion of BMW’s manufacturing operations in Germany.
BMW’s New Battery Plant Strengthens German EV Production
The 60-hectare Irlbach-Straßkirchen site is designed to supply sixth-generation high-voltage batteries to BMW’s German vehicle production network. Its location in Eastern Bavaria provides access to skilled workers, established manufacturing facilities and a network of suppliers.
BMW says the new plant will play a central role in the company’s Neue Klasse production strategy, supporting the expansion of its next generation of electric vehicles.
The project also strengthens the region’s existing automotive industry. BMW plants in Dingolfing and Regensburg have produced approximately 40% of all BMW vehicles ever manufactured, while around one-fifth of the company’s global workforce is employed across its facilities in Dingolfing, Regensburg, Landshut and Irlbach-Straßkirchen.
When fully operational, the new battery plant is expected to employ around 1,600 people and produce several hundred high-voltage batteries per day across two production lines.
Advanced Manufacturing and AI Support BMW’s Gen6 Batteries
The new plant uses advanced manufacturing technology to produce BMW’s sixth-generation, or Gen6, high-voltage batteries. The battery system features cylindrical cells integrated directly into the battery pack using a cell-to-pack design. The battery housing also forms part of the vehicle’s body structure through BMW’s pack-to-open-body concept.
Production takes place across a 50,000-square-metre manufacturing area equipped with approximately 500 robots. Artificial intelligence systems analyse production data, helping monitor manufacturing processes and identify potential quality issues.
BMW collects and monitors more than 3,500 data points for each battery during production. Every manufacturing step is documented in real time, and each completed battery undergoes a comprehensive end-of-line inspection.
Digital twins and virtual reality applications were also used before the plant opened to support production planning and employee training. According to BMW, these technologies help improve manufacturing efficiency while maintaining consistent quality standards.
The Gen6 battery concept is intended for use across BMW Group vehicle segments. The company has filed patent applications covering more than 500 innovations associated with the development of its sixth-generation eDrive technology.
How BMW Builds Its Sixth-Generation Batteries
BMW’s Gen6 battery production process begins with cells supplied by battery manufacturers. Incoming cells undergo additional measurements, including voltage checks, before being grouped and connected to cooling systems.
The cell clusters and electrical contact systems are then cleaned using lasers and welded with precision. An advanced foaming process protects the assembled components, improving the battery pack’s mechanical stability and durability.
The battery housing is subsequently closed, sealed and riveted. BMW then installs the Energy Master, the central control unit responsible for managing the high-voltage battery.
A final sealing process and comprehensive inspection complete the production cycle. BMW says its extensive monitoring and quality-control systems are designed to support highly consistent battery manufacturing.
New BMW i3 Gets a 108.7 kWh Battery and Up to 906 km of Range
One of the first vehicles to benefit from the new battery production facility is the BMW i3 50 xDrive, part of the Neue Klasse generation of electric vehicles.
The First Edition of the BMW i3 50 xDrive features a 108.7 kWh high-voltage battery and offers a claimed WLTP range of up to 906 kilometres. Its 800-volt electrical architecture supports DC fast charging at up to 400 kW.
According to BMW, the electric sedan can add up to 423 kilometres of range in 10 minutes under the specified test conditions when connected to a compatible DC fast charger.
The new BMW i3 also supports bidirectional charging, allowing energy to flow in both directions under compatible operating conditions.
These specifications highlight the role of BMW’s new battery technology in improving long-distance driving capability and reducing charging stops for future electric vehicles.
BMW Expands Its Global Battery Production Network
The Irlbach-Straßkirchen facility forms part of BMW’s broader strategy to manufacture high-voltage batteries close to its vehicle assembly plants. The company’s local-for-local approach is intended to reduce transport distances, strengthen regional supply chains and support local employment.
Alongside the German facility, BMW is establishing battery assembly operations in Debrecen, Hungary; Shenyang, China; Woodruff, United States; and San Luis Potosí, Mexico.
The strategy connects battery production more closely with vehicle manufacturing, helping BMW scale up production of Neue Klasse models across multiple markets.
BMW is also relying heavily on German suppliers for the new facility. All directly contracted construction companies came from Germany, with approximately two-thirds based in Bavaria. More than three-quarters of the plant engineering firms are German, and around one-third are located in Bavaria.
Renewable Energy and Lower-Emission Battery Production
BMW has designed the Irlbach-Straßkirchen plant to operate without fossil fuels for regular operations. A photovoltaic system generates part of the site’s electricity, while the remaining energy requirements are covered entirely by renewable sources.
The battery assembly process is also designed to require no water.
The sustainability measures extend to the battery cells themselves. A portion of the cobalt, lithium and nickel used in the Gen6 cells comes from secondary materials, while renewable energy is used in the production of anode and cathode materials and in cell manufacturing.
BMW reports that CO₂-equivalent emissions per watt-hour have been reduced by approximately 33% compared with the Gen5 cell used in the previous model generation.
BMW Connects Battery Development, Production and Recycling
The new plant is part of a wider Bavarian battery network that covers research, development, manufacturing and recycling.
BMW’s pilot facilities in Parsdorf and Hallbergmoos, together with its Research and Innovation Center in Munich, support the development and testing of battery prototypes and manufacturing processes before they are transferred to large-scale production.
The company’s Battery Cell Competence Center in Munich focuses on future cell technologies, while the Cell Manufacturing Competence Center in Parsdorf examines how cells can be produced efficiently and to demanding quality standards.
Battery recycling is another part of the strategy. BMW’s Cell Recycling Competence Center in Salching, located approximately 16 kilometres from Irlbach-Straßkirchen, began operations in December 2025. The facility uses a direct recycling process developed by BMW to recover valuable raw materials from production residues and battery cells through mechanical dismantling, avoiding energy-intensive chemical or thermal processing.
