BMW Group has outlined manufacturing steps for its sixth-generation (Gen6) high-voltage battery at Plant Woodruff in Spartanburg County, South Carolina, anchoring the $1.7 billion the automaker committed in October 2022 to localize battery pack output for the Neue Klasse electric lineup.

The disclosure describes a cell-to-pack assembly flow that drops traditional module housings and integrates the pack as a structural floor element in the vehicle. Process steps include laser-welded cell connections and direct pack-to-body mounting, both aimed at cutting part count, mass, and assembly cycle time.

What does the Woodruff investment cover?

The $1.7 billion envelope and a roughly 300-job target date to BMW's October 2022 announcement, when Woodruff was framed as a cell-manufacturing site. BMW revised scope in 2023, repositioning Woodruff as a battery pack assembly operation with cells sourced from partner suppliers. Capital intensity and ramp speed drove the change, BMW said at the time.

Production timing at Woodruff aligns with the Neue Klasse launch window, with ramp targeted for the second half of the decade. Output will feed X3- and X5-class electric SUVs built at the adjacent Spartanburg assembly plant. Pairing battery and vehicle lines on a single campus compresses logistics for the most expensive electrified component.

How does Gen6 differ from Gen5?

Gen6 replaces the prismatic cell format used in Gen5 batteries with large-format cylindrical cells paired to an 800-volt electrical system. BMW has stated the combination targets a 30 percent range improvement and faster charging versus the prior generation, though those figures remain OEM claims until EPA and WLTP certification data lands.

The cylindrical format also restructures supplier logistics. CATL, Samsung SDI, and EVE Energy — the prismatic cell suppliers for BMW's Chinese and European operations — must now qualify cylindrical lines for Gen6. North American cell sourcing for Woodruff has not been disclosed.

Cell qualification for a new format typically runs 12 to 18 months, putting U.S. partner confirmation on the critical path for Woodruff's 2026 to 2027 ramp.

Where does Woodruff fit in BMW's footprint?

Woodruff sits minutes from BMW's Spartanburg assembly complex, which builds the X3, X5, X6, X7, and XM and turns out roughly 450,000 vehicles a year. Localizing pack assembly at Woodruff supports IRA tax-credit eligibility tied to North American battery sourcing — a material consideration for the X-class Neue Klasse volume BMW expects to sell in the United States.

Woodruff sits inside BMW's broader $2.7 billion South Carolina electrification commitment, announced alongside the original cell-manufacturing plans. The combined envelope covers battery assembly, vehicle electrification, and supplier park development around Spartanburg. Workforce training for the new battery operations has already started through a partnership with state technical colleges, BMW has said.

What to watch next:

• First pre-production packs at Woodruff, expected in 2025
• Cylindrical cell capacity disclosures from BMW's supplier partners
• Named U.S. cell source for North American Gen6 output
• Neue Klasse launch at Spartanburg, starting with an X3-based electric crossover
• Whether IRA credit eligibility holds as 2025 sourcing thresholds tighten