For most EV buyers, the battery remains the most important component they never get to see. BMW is offering a first look inside its new Plant Woodruff facility in South Carolina, where the next-generation battery packs for the upcoming iX5 will be assembled.
The factory will begin series production of the sixth-generation high-voltage batteries in December 2026, supplying packs for the upcoming BMW iX5. Its location is no coincidence either. Situated just 24km from BMW's Spartanburg vehicle plant, the facility reflects the brand's approach of assembling batteries close to where vehicles are built, reducing transport requirements between the two operations.
The batteries themselves are arguably the bigger story. The iX5 will be based on BMW's latest Gen6 eDrive technology, which introduces cylindrical cells arranged using a cell-to-pack design. Combined with an 800-volt electrical architecture, the new system marks a significant step forward from the Gen5 batteries currently used by BMW's electric models.
BMW says every battery assembly stage is monitored and documented in real time. More than 250 robots work alongside over 300 employees, while AI-based systems analyse production data continuously to identify potential issues before they become defects. It's a level of traceability increasingly becoming standard in battery manufacturing, where consistency is every bit as important as outright performance.
The company has also embraced digital tools long before production starts. Employees train using virtual reality simulations built from a detailed digital replica of the factory, allowing them to familiarise themselves with equipment and manufacturing procedures before stepping onto the production floor.
When fitted to the BMW iX5 60 xDrive, the Gen6 battery will offer up to 144kWh of usable energy in the U.S.A. market and 141kWh in Europe. That makes it the largest high-voltage battery yet fitted to a fully electric BMW, while dual electric motors provide all-wheel drive through BMW's xDrive system.
One detail that stands out is BMW's focus on the battery's environmental footprint. The Gen6 cells use higher proportions of recycled cobalt, lithium and nickel, while BMW claims CO₂e emissions per watt-hour have been reduced by around 28% compared with the Gen5 battery used in today's BMW iX.
