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BMW Group has offered a first look inside its new Plant Woodruff facility in South Carolina, where series production of high-voltage batteries for the all-electric BMW iX5 is due to begin in December 2026.
The new plant will play a central role in BMW’s US electrification strategy, producing sixth-generation (Gen6) high-voltage batteries for the next generation of electric BMW X models. The facility combines advanced automation, artificial intelligence (AI), digital twins and virtual reality (VR) technology to support what the company describes as a zero-defect manufacturing approach.
“Plant Woodruff plays a key role in the ramp-up of electromobility in the US,” 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.”
BMW says the new site employs more than 300 people alongside 250 robots, with AI-powered assistants and agents analysing production data in real time. Every stage of battery assembly is monitored and documented inline, helping to improve quality and maximise Overall Equipment Effectiveness (OEE).
The company’s Gen6 battery technology uses cylindrical cells integrated directly into the battery pack using a “cell-to-pack” architecture. BMW believes the technology represents a significant advance in battery performance and manufacturing efficiency.
The use of digital tools has been embedded throughout the project. Digital twins of production systems were created before commissioning, while VR applications have been used extensively for employee training.
All production staff complete a VR training programme developed specifically for the site. Using virtual reality headsets and PCs, employees can practise manufacturing operations in a highly detailed digital replica of the factory before working on the real production equipment.
BMW says the approach helps workers gain a thorough understanding of production processes and build confidence operating machinery before the manufacturing systems enter service.
The Woodruff project has progressed rapidly since construction began. Following the official groundbreaking in June 2023, building work started three months later. Installation of manufacturing equipment commenced in September 2024 while construction was still ongoing, and preparations for production began during summer 2025. Test and pre-series batteries have already been produced on the assembly lines.
“Plant Woodruff demonstrates how quickly we can scale a new battery concept to industrial production,” said Rich Everly, Vice President of Production at BMW Group Plant Woodruff. “The key factor is the synergy between a skilled and dedicated team and the continuous exchange of experience within the production network.”
Sustainability has also been a major focus of the project. The Gen6 battery cells contain a high proportion of recycled cobalt, lithium and nickel, while renewable energy is used in the production of anode and cathode materials as well as in cell manufacturing. According to BMW, CO₂e emissions per watt-hour have been reduced by around 28% compared with the Gen5 battery cell used in the BMW iX.
The company added that Plant Woodruff does not use fossil fuels during normal operations, while hydrogen-powered industrial trucks support internal logistics.
BMW is establishing five battery assembly plants around the world under its “local for local” production strategy, locating battery manufacturing close to vehicle assembly operations. Alongside Woodruff, facilities are being developed in Irlbach-Straßkirchen in Germany, Shenyang in China and San Luis Potosí in Mexico. Series production of Gen6 batteries has already started in Debrecen, Hungary.
At Woodruff, battery cells supplied by specialist manufacturers undergo extensive testing before assembly begins. Incoming goods inspections include voltage measurements and quality checks. The cells are then clustered and connected to cooling systems before being laser-cleaned and welded. Each weld seam is monitored continuously through inline inspection systems.
An advanced foaming process follows, creating a rigid protective structure around the battery components to enhance safety, stability and durability. The battery housing is then sealed and riveted before installation of the Energy Master, the unit responsible for controlling battery functions. Every completed battery undergoes a 100% end-of-line inspection before leaving the plant.
The finished battery packs will be transported to BMW’s nearby Spartanburg vehicle factory, located just 15 miles away.
The first recipient will be the battery-electric BMW iX5, which features sixth-generation BMW eDrive technology, round battery cells and an 800-volt architecture. With an energy content of up to 144kWh in the US market, BMW says the iX5 will have the largest high-voltage battery fitted to any fully electric BMW model to date, powering dual electric drive units and the company’s xDrive all-wheel drive system.