The BMW Group is further expanding its Germany-based production capacities for electric drives. From 2021, battery cells for high-voltage batteries will be coated at BMW Group Plant Regensburg and complete high-voltage batteries will be produced from 2022.

The company is investing over $240 million in the site in order to supply the growing number of electrified BMW Group vehicles with high-voltage batteries.

BMW Group Plant Regensburg started production of two electrified models this year with the plug-in hybrid versions of the BMW X1 and the BMW X2. At the same time, with extensive investments and conversions, the plant is preparing itself so that moving forward, it can respond flexibly to changing demand for different drive types.

The production process for high-voltage batteries consists of two main steps and the battery modules are produced in a highly automated process. First, the lithium-ion cells undergo a plasma cleaning process. Specially developed equipment coats the cells to ensure optimal insulation.

The battery cells are then assembled into larger units, known as battery modules. Different battery cells are used, depending on which one provides the best characteristics for the relevant vehicle concept.

The battery modules are then mounted into an aluminium casing along with the vehicle connectors, control units and cooling units. The size and shape of the aluminium casing as well as the number of battery modules used vary depending on the vehicle variant. The result is a high-voltage battery ideally adapted to the vehicle.

This combination of standardised battery modules and casings flexibly adapted to the vehicle has several advantages. Firstly, it ensures uniform properties and quality standards in the production of the high-voltage batteries.

Secondly, the modular design of the high-voltage battery serves as the basis for a wide range of e-drive variants. Last but not least, this modular approach is a crucial prerequisite for being able to respond quickly to customer demand and take advantage of cost savings.

To date, the high-voltage batteries for all electrified vehicles of the BMW and MINI brands have been produced at the three in-house battery production facilities in Dingolfing, Spartanburg/U.S.A and Shenyang/China. In Thailand, the BMW Group has localised the production of high-voltage batteries for the Rayong plant in a cooperation project with the Draxlmaier Group.