BMW’s Plant Woodruff in South Carolina will begin series production of the Gen6 high-voltage batteries for the fully electric BMW iX5 in December, and the auto maker has revealed further details of the technology that will underpin the production process.

The facility uses AI-supported production processes, digital twins and virtual reality applications, with the auto maker stating that “the new plant is setting industry standards for the assembly of high-voltage batteries”. The BMW X5 premiered on June 30 at the auto maker’s South Carolina Plant Spartanburg facility, which it refers to as “the Home of X”.

“Plant Woodruff plays a key role in the ramp-up of electromobility in the US,” said Raymond Wittman, member of the board of management of BMW responsible for Production. “With our Gen6 high-voltage battery, we’re not only taking a major technological leap – we are also setting new standards in production. In Woodruff, we are combining cutting-edge processes, artificial intelligence and the expertise of our employees to create a production facility designed for the highest quality.”

“With Plant Woodruff, we are further expanding our footprint in South Carolina and strengthening the close integration of battery and vehicle production,” said Robert Engelhorn, president and CEO of BMW Manufacturing. “This creates the ideal foundation for the next generation of fully electric BMW X models assembled at Plant Spartanburg.”

Intelligent production for maximum quality 

The cylindrical cells are integrated directly into the high-voltage battery, based on the cell-to-pack principle. All production steps are continuously monitored inline and comprehensively documented in real time. In-house developed AI assistants and agents analyze this data and, together with more than 300 employees and 250 robots at Plant Woodruff, ensure the zero-defect battery production. At the same time, the extensive use of artificial intelligence enhances overall equipment effectiveness (OEE) in production. Well before commissioning, digital twins of production and virtual reality applications support planning and employee training.

Training in a virtual factory 

All production staff at Plant Woodruff complete a VR training program developed on-site. Within a virtual factory, they can practice real manufacturing operations under realistic conditions. This virtual environment replicates the plant’s production lines in meticulous detail, requiring only a set of VR goggles and a PC.

Three years from start of construction to series production 

Following the official groundbreaking in June 2023, construction of the plant began in September 2023. In September 2024, while construction was still under way, installation of the manufacturing equipment commenced. Preparations for production started in summer 2025, and the first test and pre-series batteries have been rolling off the assembly line since then. The series launch is scheduled for December 2026.

“Plant Woodruff demonstrates how quickly we can scale a new battery concept to industrial production,” said Rich Everly, vice president of production at BMW Plant Woodruff. “The key factor is the synergy between a skilled and dedicated team and the continuous exchange of experience within the production network.”

Gen6 battery cells with reduced carbon footprint 

The Gen6 battery cells used in the BMW iX5’s high-voltage battery include a high proportion of secondary materials in the cobalt, lithium and nickel content. Renewable energy is also used in the production of anode and cathode materials, as well as in cell manufacturing. Compared with the Gen5 cell used in the BMW iX, CO2 e emissions have been reduced by around 28% per watt-hour. Plant Woodruff does not use any fossil fuels during normal operations, while the site’s industrial trucks are powered by hydrogen.

Assembling the Gen6 high-voltage batteries 

At BMW Group Plant Woodruff, battery cells undergo a series of automated assembly and inspection processes, including voltage checks, cell clustering, laser cleaning and precision welding, with inline monitoring of every weld seam. The batteries are then foam-encapsulated, sealed and fitted with the Energy Master control unit before completing a 100% end-of-line inspection. Finished battery packs are transported to the nearby BMW Group Plant Spartanburg for vehicle assembly.

800V, with high energy content 

The first battery-electric BMW iX5 is based on sixth-generation BMW eDrive technology, featuring cylindrical cells and 800V technology. With an available energy content of 144kWh, the BMW iX5 60 xDrive boasts the largest high-voltage battery of any fully-electric BMW model to date.

Related news, UKBIC expands flexible pilot line capabilities with pouch assembly equipment

Following the opening on February 12, 2026, of its flexible pilot line, which aims to bridge the gap between laboratory-scale research and full-scale battery production, the UK Battery Industrialisation Centre (UKBIC) has added to the facility’s capabilities with the delivery of new pouch cell assembly equipment from Italy.

The pouch cell assembly kit will join the cylindrical cell assembly equipment that has already been fitted to provide expanded capabilities for UKBIC’s smaller development line.  The new equipment was built by Digatron at its factory near Verona and is currently being fitted in its bespoke space at the facility in Coventry.

Once complete, the FPL will be able to produce not only high-quality electrodes but also a range of cell formats (220×115 pouch, tabbed and tabless 21700 cylindrical, and 4695 cylindrical). It is expected the first customers will be able to use the cell assembly kit from the autumn.

Richard LeCain, chief technology officer at UKBIC, said, “Getting the pouch kit in is the final step in FPL construction, and we can now concentrate on testing and commissioning for both of our new assembly lines.

“The new equipment will play an important role in helping organizations de-risk scale-up and accelerate the commercialization of new battery technologies and will be open to smaller organizations than currently use our larger line.”

UKBIC already has cell assembly capability on its industrial scale-up line, offering customers 21700 tabbed cylindrical or 300×100 pouch cells at volume.

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Ford and Geely have formed a Europe-focused joint venture (JV) centered around Ford‘s manufacturing hub in Valencia. The JV will manufacture Ford and Geely multi-energy passenger vehicles for the European market.

By pooling production volume, the companies will maximize the capacity of the Valencia plant and reduce the cost of vehicles built there. Pending regulatory approvals, the joint venture will begin operations in the first half of 2027, with the first new vehicles scheduled to roll off the line in 2028. The Valencia plant will continue to produce the Ford Kuga in the meantime.

“This JV with Ford in Europe reflects our commitment to open, collaborative product development as part of our growth strategy, deepening our local presence and commitment to customers in Europe,” said Alex Nan, vice president of Geely Auto Group. “We are dedicated to delivering vehicles that European customers will choose on merit: on industry-leading features, on high quality and on actively contributing to Europe’s green future. Put simply: we are building cars in Europe, for Europe, alongside a trusted partner.”

Transforming Valencia

The JV will transform Ford’s Valencia facility into a shared, high-tech manufacturing hub. The plant opened in 1976 and built the original Fiesta, Ford’s first global front-wheel-drive car.

Under the proposed ownership structure, Ford will own 66% of the new entity and Geely Auto 34%.

“For nearly 50 years, Valencia has built some of the most-loved cars in our history, and now this team will help build our future,” said Jim Baumbick, the president of Ford of Europe. “That’s why we’re building a flexible, cost-effective industrial system with a capable partner in Geely Auto. Together we can fully utilize a best-in-class plant with a great workforce and match the industry’s new cost benchmark. This is all part of Ford’s vision to give European drivers rally-bred handling, true off-road capability and multi-energy technology, with a distinct Blue Oval DNA.”

The JV will combine the engineering, manufacturing and development know-how of both auto makers to build Ford and Geely low- and zero-emission passenger vehicles. The cars will be tailored for European drivers, offering them choice in powertrain technology.

Ford and Geely’s planned joint venture in Valencia will support production of several new models from 2028. Ford will continue building the Kuga alongside a new compact Bronco SUV and a jointly developed multi-energy family crossover. Geely plans to manufacture two electric SUVs at the facility as part of its European expansion strategy, with the first Geely-branded vehicles expected to enter production in 2028. According to the companies, the partnership is intended to strengthen Ford’s European product line-up while supporting Geely’s international growth.

“This partnership shows how auto makers are strengthening Europe’s industrial base, but we can’t do it alone,” said Baumbick. “What we’ve achieved in Valencia, with the ongoing support of Spain’s national and regional governments, is a masterclass in public-private partnership that sets the benchmark for the rest of Europe.”

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Celebrating the 30th anniversary of Honda Transmission Plant-Ohio (TMP-O) in Russells Point, Ohio, the company honored the manufacturing legacy. Since production began in 1996, the plant has produced the award-winning two-motor hybrid system that helps power Honda hybrid electric vehicles, continuously variable transmission (CVT) differentials for Honda and Acura all-wheel drive vehicles, and other key components.

With a total investment of more than US$1 billion, the 1.1-million ft² Ohio transmission plant employs more than 1,200 associates, with annual production capacity exceeding 1 million transmissions and gear shifts and 500,000 two-motor hybrid systems, along with transfer cases and differentials for four-wheel drive vehicles.

“For thirty years Honda associates at Russells Point have produced an incredible 26 million transmissions that have helped to power the future,” said Ohio governor Mike DeWine.  “Congratulations on achieving this incredible milestone.”

Honda began US production of transmissions at its Anna Engine Plant (AEP) in Ohio in 1989. In 1996, transmission manufacturing was relocated to Russells Point to a wholly owned Honda supplier, Bellemar Parts Industries, which was incorporated as Honda Transmission Manufacturing of America the following year.

“As we celebrate 30 years of Honda manufacturing excellence in Ohio, we’re not just reflecting on our history; we’re accelerating toward the future,” added Jason Foster, power unit manufacturing plant lead. “The unyielding continued commitment of TMP-O associates to producing top-quality drivetrains will allow us to continue building on the legacy we celebrate today.”

30 years of flexible production

TMP-O began producing 4-speed automatic transmissions in 1996, followed by 5-speed automatics in 2005 and 6-speed automatics in 2010. It now produces CVTs and the two-motor hybrid system transmission used in the Honda CR-V, Accord and Civic, and standard in the Prelude.

“For 30 years, TMP-O has stood at the center of Honda’s progress – driving innovation and demonstrating the power of passion and craftsmanship,” said Kylie Huber, TMP-O manufacturing division lead. “As the industry has evolved, both Honda Transmission Plant-Ohio and our associates have evolved with it, meeting every challenge. The legacy our associates have built over three decades is extraordinary, and it’s the reason this 30th anniversary milestone carries such deep meaning!”

Sustainability at TMP-O

TMP-O became the first major US auto manufacturing plant to source a substantial portion of its electricity directly from on-site wind turbines in 2014. In 2019, it earned the EPA’s Energy Star Certification for energy efficiency, which Honda says made it the first US automotive transmission plant to receive that recognition. More recently, plant employees installed furnace covers designed to reduce heat loss, which prevented 164 metric tons of CO₂ emissions in 2025.

Honda in Ohio

Honda has produced automobiles in Ohio for over 40 years, beginning in November 1982, with the start of automobile production at the Marysville Auto Plant (MAP), and today is the largest manufacturing employer in the state.

Honda began US manufacturing operations in Marysville with motorcycle production in 1979. Today, Honda states its Ohio manufacturing operations employ around 15,400 associates, represent a total capital investment of US$14.5 billion, and have the capacity to produce 460,000 Honda and Acura vehicles, 1.18 million engines and over 1 million transmissions annually, including two-motor hybrid systems.

Honda’s five Ohio manufacturing facilities include three auto plants (Marysville, East Liberty and the Performance Manufacturing Center), the Anna Engine Plant, and the transmission plant in Russells Point. Honda says it has invested more than US$1.3 billion in these facilities over the past five years, and its Ohio auto plants now have the flexibility to build gas-powered, hybrid and battery electric vehicles on the same production line.

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Renault has added a second production hub for its Boreal SUV in Bursa, Turkey, alongside its existing plant in Curitiba, Brazil, as it expands global production of the model. From Turkey, the model will be exported to a group of markets across Eastern Europe, the Middle East and North and Sub-Saharan Africa.

“Boreal embodies Renault’s ambition to accelerate growth beyond Europe by delivering more value to our customers and strengthening our position in the strategic C-SUV segment,” said Fabrice Cambolive, Renault brand CEO.

Unveiled in 2025 as a new international C‑segment SUV, Renault Boreal marked a first milestone with its launch in Brazil. It has since been deployed across several Latin American markets from the Curitiba production hub.

“Boreal is also a strong illustration of Renault’s brand markers in action: Electrified by Passion with the introduction of our new E-Tech full hybrid technology; Designed to be Loved through its expressive design, elegant proportions and distinctive lighting signature that create an immediate emotional connection; People-First Technology with a seamless connected experience powered by Google, advanced driver assistance systems and intuitive onboard technologies; and Crafted Space through a spacious, versatile and comfortable interior designed around the needs of modern families,” added Cambolive.

“We are very proud to introduce Boreal to the Turkish market. Being manufactured at our Oyak Renault facility in Bursa will both support domestic demand and strengthen Turkey’s position in the global automotive ecosystem by contributing to our export targets,” said Lionel Jaillet, the CEO of Renault Group Turkey.

The Boreal will be the first model to feature the new 160hp full hybrid E-Tech powertrain, complemented by the 1.3 turbo TCe EDC 145hp gasoline engine.

Efficient engine options and EDC automatic gearbox

Renault Boreal has been developed with a range of powertrain options, including the full-hybrid E-Tech 160hp, turbo TCe EDC 145hp and hybrid E-Tech 4×4 150hp versions.

In Turkey, the model will be launched with the full hybrid E-Tech 160hp and turbo TCe EDC 145hp engine options. The range will be expanded in the fourth quarter of 2026 with the addition of the hybrid E-Tech 4×4 150hp version.

The 1.3 Turbo TCe EDC 145hp gasoline engine, paired with a 6-speed wet dual-clutch (EDC) transmission, delivers a balanced mix of performance and driving comfort. This version has combined CO2 emissions of 149g/km and combined fuel consumption of 6.6 l/100km, according to WLTP standards.

The full hybrid E-Tech 160hp version runs on the HR18-coded hybrid engine manufactured by Oyak Horse in Bursa, Turkey, and exported worldwide.

The system enables up to 80% electric driving in urban use and allows electric acceleration up to 110km/h. The model, equipped with a multimode automatic gearbox, stands out with combined CO2 emissions of 108g/km and combined fuel consumption of 4.8 l/100km, according to WLTP standards.

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MG has announced that it is to build its first manufacturing facility in mainland Europe in Galicia, Spain. The new €200m (US$233m) plant is predicted to create more than 2,000 jobs across Europe and underlines the brand’s ‘In Europe, For Europe’ strategy, the auto maker said. Production is scheduled to begin in 2028, with an annual capacity of up to 120,000 vehicles.

“From technological innovation to the localization of manufacturing and R&D across Europe, supported by a truly global product line-up, MG continues to push the boundaries of what is possible – making advanced technology and sustainable mobility accessible to more people than ever before,” said William Wang, managing director, MG UK and Europe.

The site will integrate vehicle research and development, advanced manufacturing, core component supply and intelligent logistics operations, forming a fully connected, end-to-end industrial ecosystem. This platform will significantly expand localized production and sourcing, strengthening the resilience, responsiveness and agility of MG’s European supply chain.

MG will deepen collaboration with leading European technology partners, research institutions and local suppliers to accelerate innovation across key future-facing domains, including next-generation battery technology, intelligent mobility systems and clean energy solutions.

This announcement comes at a pivotal moment for the European automotive industry, as the EU’s 2035 zero-emission targets continue to accelerate the shift toward electrified mobility.

Wang said, “Through our ‘In Europe, For Europe’ strategy, we are not simply responding to the future of mobility – we are helping define it. By investing in local capabilities, strengthening our European footprint and fostering a more competitive automotive ecosystem, we are accelerating Europe’s journey toward a cleaner, smarter and more sustainable mobility future.”

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Mahle Powertrain has achieved a major milestone in Project Cavendish, successfully converting a 13-liter heavy-duty engine to run purely on hydrogen. The converted engine has matched the maximum torque of the diesel baseline engine, and measured engine-out NOX suggests that emissions can be readily maintained below 0.2g/kWh across the entire engine operating map using existing aftertreatment technology.

Launched in early 2023, Project Cavendish is a £9.8m (US$13.2m) program supported by the Advanced Propulsion Centre UK (APC) to develop end-to-end hydrogen powertrain capability for heavy-duty applications and enable the UK’s transition to net zero transportation. As part of the project, Mahle Powertrain has upgraded its testing infrastructure in Northampton for hydrogen operation.

“This milestone demonstrates that hydrogen combustion has a place as a clean fuel in the heavy-duty market,” said Jonathan Hall, head of research and advanced engineering at Mahle Powertrain. “Achieving the target torque and low raw engine-out emissions from a hydrogen-fueled 13-liter heavy-duty engine represents a significant step forward, both for Mahle Powertrain and for the wider industry, as we move toward practical hydrogen combustion solutions for heavy-duty applications.”

Achieving target torque is just the first step, says Mahle; the bigger challenge in hydrogen combustion is controlling NOX emissions. The measured raw engine-out emissions of its converted engine are very low and the addition of a simple selective catalytic reduction (SCR) aftertreatment system will enable the tailpipe emissions to be significantly less than EU VII limits. The measured particulate emissions were negligible and readily manageable using existing particulate filter technology. The results demonstrate that hydrogen combustion engines offer a practical, fast-to-market pathway toward zero-carbon heavy-duty transportation.

Project Cavendish also aims to facilitate wider hydrogen adoption by creating opportunities for external partners to undertake hydrogen engine testing at Mahle Powertrain’s facility in Northampton. The site serves as a center of excellence for the design, development, calibration and testing of all aspects of hydrogen and renewable-fuel powertrain engineering. Mahle Powertrain has reported growing interest from new customers and expects commercialization of its hydrogen and renewable fuels infrastructure to expand significantly over the coming year.

The project brings together expertise from Mahle Powertrain, Phinia, BorgWarner, Cambustion, Hartridge and Oxford Brookes University to deliver the next generation of hydrogen combustion technology.

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General Motors has announced plans to invest more than US$150m in its Saginaw Metal Casting Operations (SMCO) to support the production of the sixth generation of its V-8 engine blocks and heads used in full-size pickup trucks.

This commitment builds on the approximately US$5.5bn in investments GM made in 2025. In January 2023, the company announced a half-billion-dollar investment in its Flint Engine plant for production of the sixth generation of V-8 engines. The investment in SMCO, which includes includes new equipment and tooling, will support this work.

“This significant investment of over US$150m is a clear commitment to the plant and our people,” said John Lancaster, plant director, GM. “By enabling the production of next-generation engine blocks and cylinder heads for full-size trucks, the plant is well-positioned for the future. This not only secures existing jobs but also strengthens the local economy and ensures the plant continues to be an integral part of the automotive supply chain.”

SMCO will continue to produce the fifth generation of GM’s V-8 engine blocks while the plant prepares for the next generation’s production start in 2027.

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Valeo has inaugurated a manufacturing line for electric powertrain systems at its Pune, India, plant. The company has been selected by Mahindra to provide the electric powertrain of its latest Born Electric platform.

The Pune facility features advanced manufacturing capabilities to produce the  3-in-1 e-Axle integrating the motor, its inverter and reducer into a compact and efficient system that will equip the latest models. The integrated 3-in-1 eAxle leverages the latest iteration of Valeo’s motor technology.

Xavier Dupont, Valeo Power CEO, said, “India is a key region in Valeo’s Elevate 2028 strategic plan. Our investments in Pune support our commitment to deeper localization of advanced technologies in India. By localizing the production of our highly integrated 3-in-1 e-Axle systems, we are strengthening our ability to deliver advanced technologies to our customers and contributing to India’s transition toward safer and more sustainable mobility.”

Located at Valeo’s Pune plant in Lonikand, the facility is equipped with advanced manufacturing capabilities. It includes automated manufacturing lines for U-pin or hairpin winding stator assembly, reducer assembly, inverter manufacturing and final e-Axle assembly. These lines incorporate advanced automation, precision assembly processes and rigorous quality control systems, supported by full digitalization and end-to-end traceability.

Jayakumar G, president of Valeo India, added, “The inauguration of this line marks an important milestone in Valeo’s journey in India. Our new e-Axle manufacturing line in Pune is a key step in our growth strategy. It reflects our commitment to bringing advanced technology solutions closer to our customers. We are proud to develop and manufacture this e-Axle for Mahindra’s Born Electric vehicles and to contribute to the growth of India’s EV ecosystem.”

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The company-wide kAIros AI initiative aims to improve efficiency in support of the company’s ambitions to reduce time-to-market by nearly 50%, cut low-value process work by 40% and increase design cycle efficiency by 25%. Supported by Nvidia, Google Cloud and Deloitte, kAIros is intended to enhance how the company designs, engineers, manufactures and operates across its business.

kAIros is part of Horse Powertrain‘s wider strategy to strengthen the competitiveness of advanced manufacturing in Europe through the use of AI in development, simulation and industrial operations. By combining advanced supercomputing with cloud platforms, the company aims to provide the computing power, security and scalability needed to support these activities and enhance its long-term innovation capabilities.

AI Factory to support industrial AI applications 

At the heart of kAIros is the Horse Powertrain AI Factory, supporting AI use cases across engineering and production, including model training, simulation and digital twins, with the aim of accelerating industrial innovation and real-world deployment. A key part of the concept is the generation of training data to help continuously improve models and digital twins over time.

These capabilities enable the company to run advanced simulations and optimize operations in real time across products, factories, warehouses and logistics, with Google Gemini Enterprise used to deploy AI agents across the business, helping reduce coordination tasks that add limited value.

kAIros also supports physical AI by linking real-world operations with virtual systems in real time. This enables systems to interpret their environment, support autonomous decision-making, and interact with cobots, automated guided vehicles and smart machines. Applications include automated video-based quality inspection, faster product simulation and robotics for process optimization.

A dedicated Center of Excellence will lead the development of internal AI capabilities, bringing together cross-functional teams to build applications and scale expertise across the organization. Alongside this, the AI Factory will support scenario simulation, algorithm optimization and the development of intelligent propulsion solutions to improve efficiency and predictive performance. The initiative also aims to build long-term industrial AI capability to support advanced manufacturing in Europe.

Patrice Haettel, COO of Horse Powertrain and chief executive officer of Horse Technologies, said, “Industry advances at moments when technology doesn’t just follow change – it drives it. With kAIros, we are taking a decisive step into a new era where AI can redefine speed, cost, efficiency and sustainability.

“Our goal is to turn data into knowledge, simulations into real value, and innovation into competitive advantage. Horse Powertrain aims to be more agile and reliable because we understand that AI is not just a tool and kAIros is among the first AI factories in Europe for the automotive industry.”

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