BMW has begun series production of its Gen6 high-voltage batteries at its Shenyang plant. Shenyang is the third site in the company’s new global Gen6 battery network, following Debrecen in Hungary and Irlbach-Straßkirchen in Germany.
The batteries made there will supply future Neue Klasse models built in China. BMW Board member Raymond Wittmann, responsible for production, said the start in China shows how quickly the company is industrializing its latest technology worldwide, and that it is a key condition for ramping up the Neue Klasse globally.
What Gen6 Changes
Compared with the previous cell generation, the new cylindrical cells deliver more than 20 percent higher energy density, and charging speed and range improve by up to 30 percent.
A cell-to-pack design integrates the cylindrical cells directly into the housing and removes the conventional module level, making better use of installation space and allowing the battery to fit different models.
A BMW-developed central control unit called the Energy Master sits on the battery and combines key power-supply and battery-management functions.
A Network Built Near the Vehicle Plants
The batteries are made close to the vehicle plants, which BMW says shortens transport routes, stabilizes supply and strengthens resilience. Battery assembly in Woodruff, USA, and San Luis Potosí, Mexico, will begin series production in the coming months.
All sites follow uniform production, quality and safety standards, while each contributes regional manufacturing and supplier expertise.
From Cell to Finished Pack
Cells are inspected and joined with cooling units to form clusters, then laser-cleaned and precision-welded to the contact system. A foaming process bonds the parts into one mechanical unit.
The housing is closed, sealed and riveted, the Energy Master is installed, and every battery passes a complete end-of-line test.
Throughout, production data is captured and analyzed, with digital twins, AI-supported inspection and inline monitoring of laser-welded joints aimed at catching deviations early and ensuring traceability.