BMW’s Electric Revolution: Neue Klasse and the Future of Driving
The BMW Group has taken a giant leap forward in electric drive technology, paving the way for an all-electric future. At the Tech Days event in Landshut, the company presented initial details of its sixth-generation BMW eDrive technology, which will power the fully electric Neue Klasse vehicles. The first Neue Klasse model is slated to begin series production later this year.
Key Technological Advancements
The forthcoming technology showcases several key advancements:
- BMW Energy Master: An intelligent central control unit for the high-voltage battery, developed and produced in-house at Plant Landshut.
- High-Voltage Battery Concept: This concept, combined with the BMW cylindrical cell, promises significant breakthroughs in energy density, charging speed, and vehicle range.
- Electric Motor Versatility: BMW demonstrates technology-openness via the use of different electric motor types: SSM and ASM.
- Modular Approach: Electric motor production utilizes a modular blueprint, providing exceptional flexibility.
- Value Chain Integration: BMW is integrating expertise from the entire electric mobility value chain within Bavaria and Austria, including development, procurement, production, and recycling.
Charging Faster, Driving Further
With the sixth-generation BMW eDrive technology (Gen6), BMW is making a major leap. Product improvements include a 30% faster charging speed and a 30% increase in range, with higher figures for specific models. The Gen6 high-voltage battery concept utilizes the new 800V technology. This technology is set to debut in the Neue Klasse and will be incorporated into all fully electric BMW Group models.
The Gen6 high-voltage batteries are designed for use across all vehicle segments, including high-performance BMW M GmbH models. The new, slimmer design allows for integration across different models, irrespective of vehicle height. The high-voltage battery also functions as a structural component in the Neue Klasse’s body, with new cylindrical cells integrated directly into the battery (“cell-to-pack”).
The new BMW cylindrical cell features a 20% higher energy density than its Gen5 prismatic battery cell counterpart. Bidirectional charging will come standard, with Gen6 models supporting this capability.
BMW Energy Master: The Brains of the Operation
The BMW Energy Master is a central control unit located within the high-voltage battery. This unit manages both high- and low-voltage power, as well as data from the battery. It also controls the power supply for the electric motor and the car’s electrical system. In addition, it ensures the safe and intelligent operation of the high-voltage battery. BMW has filed new patent applications for the vehicle’s electrical system, including electronic fuses.
Both the hardware and software for the Energy Master were developed entirely in-house, allowing for independent, real-time implementation of updates using Remote Software Upgrades. This is a specific convenience for customers.
Localized Production and Supply Chain
“Local for local” is the approach BMW is taking for high-voltage battery assembly, with five new production facilities located near its vehicle plants. Assembly plants for Gen6 batteries are being developed in Irlbach-Straßkirchen (Lower Bavaria), Debrecen (Hungary), Shenyang (China), San Luis Potosí (Mexico) and Woodruff (South Carolina, USA). This strategy secures production and guarantees jobs. The supplier network for battery cells will work with five battery cell factories across Europe, China, and the United States.
Advanced Production Techniques
The Gen6 high-voltage batteries are produced using “cell-to-pack” and “pack-to-open-body” methods. “Cell-to-pack” places the cylindrical cells straight into the high-voltage battery housing. “Pack-to-open-body” refers to the high-voltage battery’s new role as a structural element in the vehicle.
Made in Germany and Austria
The core expertise in battery production is centered in Bavaria. The Energy Master is produced at Plant Landshut, which distributes it to all high-voltage battery assembly plants. The electric motor with the sixth-generation BMW eDrive technology is developed at Plant Steyr in Austria, which also functions as a development center for electric drive systems and thermal management.
Plant Landshut’s Role
Plant Landshut plays a crucial part in the Neue Klasse project. It is investing heavily to increase annual production volume for the electric motor housings. The plant’s innovative Injector Casting (ICA) process is used to create highly complex aluminum housings that support lightweighting. The Energy Master’s production is starting on the first production line in August 2025, with further expansion to follow in mid-2026.
Modular Approach to Manufacturing
The modular manufacturing system for the Energy Master was created entirely in-house. This modular approach provides cost savings and allows the company to react rapidly to market demands. The production system uses a high degree of automation for efficiency and 100-per-cent end-of-line system checks for quality.
Recycling Initiatives
BMW is expanding its focus on high-voltage battery recycling. In a partnership with SK tes, cobalt, nickel, and lithium are recovered from end-of-life batteries. BMW is also working with Encory, its joint venture, to set up a competence center for battery cell recycling in Lower Bavaria.
Electric Motor Innovation
The BMW Group has retained the electrically excited synchronous motor (EESM) for its Gen6 power unit. This synchronous motor has an adjustable magnetic field in the rotor and delivers excellent efficiency and consistent power output. The Gen6 powertrain also uses an asynchronous motor (ASM). These ASM motor variants will be fitted at the front axle of Neue Klasse cars with BMW xDrive.
Enhanced Benefits
Compared to a Gen5 xDrive model, a Neue Klasse model utilizing both EESM and ASM technology boasts improvements such as:
- Energy losses reduced by 40%
- Costs reduced by 20%
- Weight reduced by 10%
By combining various types of electric motors, the BMW Group’s technology-open approach is apparent in electric mobility. Customers will be able to select models with one, two, three, or four electric motors.
The sixth-generation BMW eDrive technology is a major factor in the overall vehicle efficiency gain of approximately 20 percent for the Neue Klasse.
Electric Drive Systems: Made in Steyr
Mass production of the Gen6 electric drive systems will begin at BMW Group Plant Steyr in summer 2025. By 2030, the BMW Group will have invested over one billion euros at the site to develop its electric drive system expertise. All key components of the electric drive unit, including the rotor, stator, transmission, inverter, and housing, will be produced at Steyr. The Steyr plant has significant experience in combustion engine production, making it an ideal site for electric motors.
Thermal Management
Thermal management is critical for a host of performance parameters, including range, consumption, acceleration, and charging time. Efficient thermal management is important for fast charging. The Steyr site develops thermal management systems for all BMW Group electric vehicles.
Plant Landshut: Component Manufacturing
Plant Landshut is the world’s largest component plant for the BMW Group, providing components to all the company’s vehicle and powertrain production facilities.
