BMW looks to increase US Gen6 assembly to avoid trade war

BMW is ramping up its production of battery systems in the US to accommodate its next-generation Gen6 800V electric vehicle technology and avoid potential tariffs on vehicles and semiconductors. The sixth iteration of BMW eDrive technology will be featured in all fully electric Neue Klasse vehicles, with the initial model slated for series production later this year at Plant Debrecen in Hungary.

The innovative battery pack design for the Neue Klasse introduces a structural pack-to-open-body concept that eliminates the need for an enclosure. Instead, new cylindrical cells are directly integrated into the 800V battery, revolutionizing the production process for BMW.

BMW has strategically established five new production facilities near its vehicle plants to assemble the high-voltage batteries for the Neue Klasse, following a "local for local" approach. These assembly locations are spread across Lower Bavaria, Hungary, the US, China, and Mexico, ensuring production continuity in the face of unforeseen political and economic challenges.

Furthermore, the BMW Group has secured agreements with various partners for the supply of battery cells from five factories located in Europe, China, and the USA to meet the demand for Gen6. The new cylindrical battery cell boasts a 20% higher energy density than its predecessor, Gen5, and supports bidirectional charging capabilities.

Prior to the global series production of high-voltage batteries, rigorous testing will be conducted on pre-series batteries at BMW Group pilot plants in Parsdorf, Hallbergmoos, and Munich. The company's expertise in product and process development is concentrated in Bavaria, laying a solid foundation for the upcoming production phase.

Dr. Joachim Post, Member of the Board of Management of BMW AG, Purchasing and Supplier Network, emphasized the company's commitment to electric mobility as a key growth area. The BMW Group's technology-open approach acknowledges the diverse mobility needs across different regions worldwide, positioning them as leaders in drivetrain technology.

The culmination of the Gen6 800V platform is the BMW Energy Master, a central control unit situated on the high-voltage battery. This unit serves as the interface for high- and low-voltage power supply, data transmission, and power regulation for the electric motor and vehicle electrical system, ensuring safe and efficient battery operation.

BMW has filed numerous patent applications for the vehicle electrical system, including electronic fuses, underscoring their commitment to innovation. The Energy Master's hardware and software were internally developed to enable real-time Remote Software Upgrades for vehicles, enhancing flexibility and functionality.

Production of the Energy Master will be centralized at Plant Landshut, supplying high-voltage battery assembly plants worldwide. The manufacturing process incorporates cutting-edge technologies such as AI-based camera systems and end-of-line system checks in a controlled environment to ensure quality and precision.

BMW's modular manufacturing system for the Energy Master, designed in-house, streamlines production and enhances supply chain efficiency. By controlling critical components like semiconductors, BMW can swiftly adapt to market demands while maintaining cost-effectiveness and supply chain resilience.