The BMW Group has started series production at Plant Woodruff in South Carolina, a new site that assembles sixth-generation (Gen6) high-voltage batteries. The packs go to Plant Spartanburg, 24 km (15 miles) away, for the new BMW iX5, the company’s first fully electric model assembled in the United States. Woodruff is the fourth plant in BMW’s Gen6 network to begin series production.
Battery assembly close to Spartanburg
The BMW Group has officially opened Plant Woodruff in South Carolina, and the opening marks the start of series production. The site assembles Gen6 high-voltage batteries for the new BMW iX5 and for future electric vehicles built at Plant Spartanburg. Spartanburg is the largest plant in BMW’s global production network.
The two sites are 24 km (15 miles) apart. BMW calls this approach “local for local”: the company builds battery assembly next to the vehicle plants it supplies. The iX5 is BMW’s first fully electric model to be assembled in the US, and the company describes Woodruff as the foundation for series production of fully electric BMW vehicles on the American continent.
Electromobility is our most important growth area. That is why we are systematically electrifying our portfolio, with the US playing a key role: By 2030, we will be assembling at least six fully electric models at Plant Spartanburg.
That was Raymond Wittmann, the BMW AG board member responsible for production. Robert Engelhorn, President and CEO of BMW Manufacturing Co., LLC in Spartanburg, linked the opening to an earlier promise: “We said we would begin assembling fully electric BMW vehicles in the US by the end of 2026 – and we are delivering on that commitment.”
South Carolina Governor Henry McMaster attended the groundbreaking. “Just a few years ago, I stood on this site with BMW leadership to break ground on this facility. Today, we are seeing that investment come to life and marking another milestone in BMW’s commitment to South Carolina,” he said.
Five Gen6 battery plants on three continents
Woodruff follows Debrecen (Hungary), Irlbach-Straßkirchen (Germany) and Shenyang (China) in starting series production of Gen6 batteries. Debrecen has produced them since October 2025, and Irlbach-Straßkirchen and Shenyang followed in October 2026. A fifth site, San Luis Potosí in Mexico, is due to follow in 2027.
This gives BMW Gen6 battery assembly in Europe, Asia and North America. The company says this is a key prerequisite for building its fully electric Neue Klasse vehicles on three continents.
How the batteries are built
Woodruff does not make battery cells. BMW buys the cylindrical round cells from established cell manufacturers, who build them to BMW’s specifications, and keeps its own cell expertise at competence centres in Bavaria. The cells are integrated directly into the pack on a “cell-to-pack” principle.
When cells arrive, they get extra checks, such as voltage measurements. They are then clustered and connected to coolers. The cell clusters and contact system are laser-cleaned and welded, and an inline system monitors every weld seam in real time. A foaming process then bonds the components into one mechanical unit. Finally, the housing is closed, sealed and riveted, and the Energy Master control unit is fitted. Every battery goes through a 100 percent end-of-line inspection.
The plant employs more than 300 people working alongside around 250 robots. In-house AI assistants and agents analyse production data in real time. BMW says this supports its zero-defect target and improves overall equipment effectiveness. Digital twins and virtual reality were used to plan the plant, and all production staff train in a VR copy of the factory before working on the real lines.
Just over three years from construction to production
The groundbreaking took place in June 2023, and construction began that September. Equipment installation started in September 2024, while the building was still under construction, and the first test and pre-series batteries were built in summer 2025.
With today’s opening of Plant Woodruff, we demonstrate how quickly we can scale a new battery concept to industrial production.
That was Rich Everly, Vice President responsible for manufacturing at Plant Woodruff.
Gen6 claims: more range, faster charging, lower emissions
BMW says the new round cells offer more than 20 percent higher energy density than the previous cell generation. The company also claims charging times up to 30 percent shorter and 30 percent more range, or more in some models.
The Gen6 cells for the iX5 contain a high share of secondary cobalt, lithium and nickel. Renewable energy is used to produce the anode and cathode materials and to manufacture the cells. According to the manufacturer, CO₂e emissions per watt-hour are around 28 percent lower than for the Gen5 cell used in the BMW iX. Woodruff uses no fossil fuels in normal operation, and its industrial trucks run on hydrogen.
What it means
Building packs next to the vehicle plant shortens the supply chain for BMW’s US electric models and ties battery output directly to Spartanburg’s production. With at least six fully electric models planned for Spartanburg by 2030, Woodruff is central to BMW’s North American EV plans.
Facts: BMW Group Plant Woodruff
- Location: Woodruff, South Carolina, USA
- Distance to Plant Spartanburg: 24 km (15 miles)
- Product: Gen6 high-voltage batteries (cylindrical cells, cell-to-pack)
- First vehicle supplied: BMW iX5
- Workforce: more than 300 employees, around 250 robots
- Timeline: groundbreaking June 2023; construction from September 2023; equipment installation from September 2024; pre-series batteries summer 2025
- CO₂e per Wh: around 28 percent lower than the Gen5 cell in the BMW iX (manufacturer figure)
Series production at Woodruff is now under way, with batteries going to Spartanburg for the BMW iX5.
Source: newsroom.bmwgroup.com