BMW Group Plant Woodruff starts series production of Gen6 high-voltage batteries for iX5 in December
BMW Group's Plant Woodruff in South Carolina will begin series production of high-voltage batteries for the new fully-electric BMW iX5 in December 2026, using AI and VR to ensure zero-defect quality.
- 144 kWh
- 28%
- 300+
- 250
What Happened
BMW Group Plant Woodruff in South Carolina will begin series production of high-voltage batteries for the new fully-electric BMW iX5 in December 2026. The plant uses AI-supported processes, digital twins, and virtual reality to ensure zero-defect production. More than 300 employees and 250 robots will work together, with all steps monitored in real time. Production staff complete VR training in a virtual factory before operating actual equipment.
Official groundbreaking
Construction begins
Equipment installation starts
Pre-series production starts
Series production launch
“Plant Woodruff plays a key role in the ramp-up of electromobility in the US. With our Gen6 high-voltage battery, we’re not only taking a major technological leap – we are also setting new standards in production.”
144 kWh (US) / 141 kWh (EU)net
Largest battery in any fully electric BMW to date.
The Gen6 battery cells use a high proportion of secondary materials and renewable energy, reducing CO₂e emissions by about 28% per watt-hour compared to Gen5. Plant Woodruff operates without fossil fuels and uses hydrogen-powered industrial trucks. The high-voltage batteries are transported just 15 miles to Plant Spartanburg for vehicle assembly. The plant is part of BMW's 'local for local' strategy, with five global production facilities for Gen6 batteries.
Why this matters
This plant marks BMW's move to produce its own Gen6 high-voltage batteries in the US, supporting local EV production and jobs. The use of AI, digital twins, and VR training aims for zero-defect manufacturing, which could improve reliability and cost. Production close to the Spartanburg vehicle plant strengthens BMW's US footprint and reduces logistics.
Terms in This Story
- Gen6
- Sixth-generation BMW eDrive technology featuring cylindrical round cells and 800-volt architecture.
- Cell-to-pack
- A battery design where cells are integrated directly into the pack without intermediate modules.
- Digital twin
- A virtual replica of a physical system used for simulation, monitoring, and optimization.
Summarised from the linked release; details can be imperfect — always verify against the original source.