BMW Gen6 high-voltage batteries: global plants, CATL supply, direct recycling

BMW starts series production of Gen6 batteries for Neue Klasse with CATL, EVE Energy supply, pilot plants in Bavaria and direct recycling in Lower Bavaria.

BMW Group is stepping up its game in the electric vehicle race, gearing up for series production of its sixth-generation high-voltage batteries — a core element for the Neue Klasse line-up. By the end of 2025, the first fully electric models, including the anticipated new electric 3 Series, will roll off the production line at the Debrecen plant in Hungary.

Bavaria once again takes centre stage as a testing ground for cutting-edge technology. In Parsdorf, Hallbergmoos and the Munich Research and Innovation Centre (FIZ), hundreds of engineers and specialists assemble Gen6 prototypes, test new processes and refine every production step. Parsdorf alone now employs over 350 people, while Hallbergmoos, located near Munich Airport, not only develops battery assembly technology but also serves as a blueprint for the upcoming Woodruff plant in South Carolina.

Zero-defect quality is a top priority. BMW relies on intelligent AI-supported systems, in-line weld seam inspections and digital twins for training and logistics. The high-voltage batteries are more than just an energy source — they are a structural part of the vehicle body. The new Energy Master unit, developed and produced in Landshut, oversees battery safety and power management.

Sustainability is also on the agenda: in Kirchroth, Lower Bavaria, BMW and Encory are building a Battery Cell Competence Centre using a direct recycling process that avoids conventional chemical or thermal treatment.

Staying true to its "local-for-local" principle, the company is launching five battery assembly sites across three continents. The supply chains are designed to remain stable even under unexpected geopolitical or economic developments, minimising reliance on distant suppliers.

Strong partnerships underpin this strategy: CATL and EVE Energy will supply the cylindrical cells for Neue Klasse models. BMW claims that thanks to Gen6, range will improve by up to 30% while production costs drop by 50% compared to previous generations — figures the company confidently sets against competitors, including Tesla.

Judging by the scale and speed of these investments, one thing is clear: the Bavarian group is not just expanding production — it is steadily building its own ecosystem for an electric future, with a strong focus on closed-loop recycling, localisation and technological independence.