WOODRUFF, USA: In December 2026, the new BMW Group Plant Woodruff in South Carolina, United States will begin series production of high-voltage batteries for the new fully-electric BMW iX5.
With AI (artificial intelligence)-supported production processes, digital twins and virtual reality applications, the new plant is setting industry standards for the assembly of high-voltage batteries.
“Plant Woodruff plays a key role in the ramp-up of electromobility in the United States,” said Raymond Wittman, member of the Board of Management of BMW AG responsible for Production.
“With our Gen6 high-voltage battery, we’re not only taking a major technological leap – we are also setting new standards in production. In Woodruff, we are combining cutting-edge processes, artificial intelligence and the expertise of our employees to create a production facility designed for the highest quality.”
The BMW Group has established state-of-the-art, intelligent and efficient production processes for its in-house developed sixth-generation (Gen6) high-voltage battery.
The new cylindrical cells are integrated directly into the high-voltage battery, based on the “cell-to-pack” principle.
All production steps are continuously monitored inline and comprehensively documented in real time.
In-house developed AI assistants and agents analyse this data and, together with more than 300 employees and 250 robots at Plant Woodruff, ensure the zero-defect battery production.
At the same time, the extensive use of artificial intelligence enhances Overall Equipment Effectiveness (OEE) in production.
Well before commissioning, digital twins of production and virtual reality applications support planning and employee training.
All production staff at Plant Woodruff complete a VR training program developed on site.
Within a virtual factory, they can practice real manufacturing operations under realistic conditions.
This virtual environment replicates the plant’s production lines in meticulous detail, requiring only a set of VR goggles and a PC.
The training helps employees develop an understanding of relevant processes and builds confidence in operating the equipment before using the actual manufacturing systems for the first time.
Installation of the Gen6 high-voltage batteries takes place at five new production facilities, which the BMW Group is building close to its vehicle plants, in line with its “local for local” principle.
In addition to Woodruff, high-voltage battery assembly plants are also being built in Irlbach-Straßkirchen (Lower Bavaria), Shenyang (China) and San Luis Potosí (Mexico).
The latest generation of high-voltage batteries has been in series production in Debrecen, Hungary, since October 2025.
