BMW Gen6 high-voltage batteries with AI-driven quality

BMW Group presents Gen6 batteries with AI-supported quality checks, digital twins and zero-defect production. New global plants prepare for series launch in 2025.

The high-voltage battery is emerging as the true core of every electric vehicle, and BMW Group is making it the focal point of its future strategy. With the sixth generation (Gen6) of eDrive batteries, the company is introducing a major shift: 46-millimeter cylindrical cells, higher energy density, faster charging, and an increase of up to 30 percent in range compared to the previous generation.

To prepare for large-scale production, BMW is building five assembly sites across Germany, Hungary, China, Mexico, and the United States. Pilot plants in Parsdorf and Hallbergmoos, along with the Research and Innovation Center (FIZ) in Munich, are already serving as testing grounds where processes are refined before being scaled to full-scale factories.

Much of the digital backbone falls under the responsibility of Patrick Zimmermann, a data scientist and IT project manager. His team ensures that every strand of data, from factory-floor sensors to cloud platforms, is seamlessly connected. BMW relies on OPC UA standards to link machines and create digital twins directly at the plants. This allows data to be standardized globally and process improvements to be rolled out simultaneously across all sites.

Quality is central to the Gen6 program. The concept of “zero defects” defines the production approach: AI-powered checks monitor every stage in real time, from laser welding and seam inspection to final housing and sealing. An innovative foaming process adds extra protection, and each high-voltage battery undergoes a 100 percent end-of-line inspection before approval.

Sustainability is equally critical. BMW reports a 60 percent reduction in CO₂ emissions for cell production compared with the current generation, achieved by using renewable electricity and integrating recycled materials. In fact, half of the cobalt, lithium, and nickel used in the Gen6 cells will come from secondary sources.

The outlook is clear: these batteries will power the upcoming Neue Klasse models, scheduled for launch at the end of 2025. For BMW, this is not only a leap into a new technological era but also a chance to set benchmarks for the industry as a whole.