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.

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Nissan has announced a multi-year agreement to supply its Formula E GEN4 powertrain to Andretti Formula E from Season 13 of the ABB FIA Formula E World Championship onward.

Formula E is a key pillar of Nissan’s global electrification strategy, making success in the championship an important part of the company’s long-term ambitions. As one of Formula E’s longest-standing competitors, Andretti Formula E has consistently competed at the front of the field, securing the 2023 FIA Formula E Drivers’ World Championship with Jake Dennis.

Beyond supplying powertrains, Nissan and Andretti Formula E will work closely throughout the GEN4 era, combining technical expertise, engineering knowledge and sporting experience. With four Nissan-powered cars competing in the series, the organizations say the collaboration will create valuable opportunities for technical exchange and continuous development, helping them both maximize performance in one of world motorsport’s most competitive championships.

Guillaume Cartier, chief performance officer at Nissan Motor, said, “Formula E continues to play an important role within Nissan’s global electrification strategy. Our collaboration with Andretti Formula E and TWG Motorsports supports our goals in the sport and strengthens our commitment to the championship. We look forward to leveraging each other’s expertise to achieve success on and off the track, demonstrating our leadership in our respective industries and generating excitement to audiences around the world.”

The collaboration also benefits from the expertise of two FIA Formula E Drivers’ World Champions. Reigning title holder Oliver Rowland and Andretti Formula E’s Jake Dennis will both contribute their experience and technical feedback as the partnership develops through the GEN4 era.

Roger Griffiths, team principal at Andretti Formula E, added, “With a motorsports legacy lasting over 80 years and multiple wins and championships across a diverse range of categories including the current Formula E World Drivers’ Championship, Nissan has more than proven its pedigree at the highest echelons of the sport. As an early pioneer of electric vehicles, Nissan has developed vast knowledge in this category and, through its time in Formula E, has shown how immensely competitive it can be. It’s these characteristics that align so well with the approach of Andretti Formula E and why we are extremely proud to be aligned with the Japanese manufacturer entering the highly anticipated GEN4 era in Formula E.

Tommaso Volpe, managing director and team principal of the Nissan Formula E Team, concluded, “We’re delighted to welcome Andretti Formula E as our customer team for the GEN4 era. Formula E is an increasingly competitive championship, and having a strong partner is an important part of maximizing both performance and technical development. Andretti is one of the most successful names in motorsport, including Formula E, where it has established itself as one of the leading teams in the sport, consistently competing at the front and securing a Drivers’ World Championship. We look forward to working closely together and building a strong partnership.”

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The WT1500 by Yokogawa Test & Measurement is a high-precision power analyzer for renewable energy, electrified vehicle (xEV), semiconductor and battery testing applications. The instrument offers four measurement channels in a 2U, 19in rack-mount chassis. It supports input voltages of up to 2,000V DC and includes resolver signal input for motor evaluation without additional equipment. Yokogawa says upcoming multi-unit synchronization will enable up to five WT1500 units to be connected, providing up to 20 power measurement channels.

Development background

Continued growth in xEV technologies and renewable energy is accelerating demand for evaluation, testing and production capabilities built around high-voltage equipment. Target voltages within these systems can reach the thousands, requiring specialized high-voltage divider equipment in typical analysis setups. These dividers can introduce measurement errors, reducing overall accuracy while complicating wiring and equipment installations. Additionally, conventional motor efficiency measurements require separately measured power and resolver signals to be synchronized on a PC.

Existing power analyzer models lacked the required voltage input range for energy storage systems (ESS), power conversion systems (PCS) and resolver support motor testing, or were too large to fit within conventional rack-mounted or desk-based setups. The WT1500 reportedly addresses this gap, delivering the necessary capabilities and functionality while eliminating the need for high-voltage dividers for systems up to 2,000V, all within a compact 19in-wide, 2U height design.

High performance

The WT1500 achieves a total power accuracy of ±0.038% (DC, 50/60Hz) and low-power-factor accuracy of ±0.07% of S at 50/60Hz, the best DC accuracy figures of the WT series, and supports two types of input elements: high voltage (HV) and wide bandwidth (WB). The HV element supports direct measurement up to 2,000V DC and 300kHz, ideal for high-voltage PCS and ESS applications. The WB element supports up to 1,000V with a 2MHz bandwidth, crucial for measuring the complex, high-frequency waveforms generated in modern xEV motors. Both inputs share a common sensor input and can be mixed in a single unit.

System integration and a space-saving design

The WT1500’s compact 2U height (approximately 88mm) design supports four power measurements and four motor evaluations, including encoder and resolver signal inputs, IEEE 1588 time synchronization and data output to CAN/CAN FD buses, and low-latency data transmission via UDP communication. It is equipped with a variety of interfaces for remote control via PC, external monitor or tablet and features a small front panel for straightforward connection setup or even to be used as a standalone instrument. The WT1500’s space efficiency allows easy integration into evaluation system racks.

Scalable measurements

For measurements requiring more than four channels, up to five WT1500 units can be synchronized, enabling 20-channel power measurement. One unit acts as the main controller, directing subunit configuration and consolidating data acquisition. Multi-unit synchronization support will be released soon.

The WT1500 also features four unique current input terminals, alongside its voltage terminals, providing power for current sensors. These, in combination with a series of new current adapters that are provided as accessories, enable the WT1500 to accommodate a wide variety of sensors: the CT Series solid-core (D-sub Terminal, 60A to 2,000A, AC-DC), the CT1000S split-core (BNC, 1,000A, AC-DC) and AC-only current clamp probes (BNC, 50A and 200A class).

The WT1500 is designed for a range of power measurement applications, including four-channel measurement of single-phase and three-phase systems with PC-based configuration and data acquisition. It also supports testing of two-system inverter motors and e-axle systems using dual- or single-unit configurations, as well as multi-unit simultaneous measurement and high-voltage testing of energy storage and power conversion systems.

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Following the opening of its flexible pilot line on February 12, 2026, 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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Cortec has researched how its VpCI-649 BD corrosion inhibitor is being used by several diesel engine manufacturers during hot engine testing and storage. Added to the engine cooling system during testing, the product is intended to protect internal components from corrosion caused by residual water. Cortec says it is also being assessed for use in smaller automotive engines with aluminum components

Why protect engines during hot testing and cold storage?

Residual water left after hot engine testing and fill-and-flush operations can contribute to corrosion of internal engine components during storage. According to Cortec, VpCI-649 BD leaves a protective film of vapor-phase corrosion inhibitors that helps protect engine internals, including where residual moisture is present.

A cure for engine corrosion

In May 2023, a major manufacturer of off-road engines began full-scale testing of VpCI-649 BD to address corrosion concerns. The product is reportedly used as a 3% solution in the cooling system during hot testing and as a 5% solution, combined with glycol, for engines stored in cold climates. Eight months into the trial, the engine maker pronounced its corrosion problem cured. Although VpCI-649 BD was initially used to protect the cast iron of very large engine blocks, it is now being considered for smaller engines with aluminum components, such as those in the automotive industry.

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Intelligent e-drive systems manufacturer InfiMotion Technology hosted a technology showcase in Wuxi, China, on July 16, marking its first public appearance as an independent supplier to the global automotive industry. The company highlighted its capabilities across research and development, validation testing and precision manufacturing for new-energy vehicle (NEV) drivetrain systems.

Joe Lin, CEO of InfiMotion Technology, said, “We have spent years perfecting our e‑drive technology for leading global auto makers, and we are now ready to stand on our own as a trusted partner for the wider market.”

Engineering without borders 

InfiMotion’s R&D network spans Wuxi, Shanghai, Ningbo, Hangzhou and Gothenburg, comprising more than 1,000 engineers, including a team of over 100 in Sweden. According to the company, its development and validation activities cover a range of operating conditions, including high-speed testing on European highways, cold-weather testing in the Nordic region and high-temperature testing in Southeast Asia to support global vehicle applications.

Extreme testing 

InfiMotion adheres to ASPICE Level 3 processes and ASIL-D (ISO 26262) certification. Its validation system includes temperature cycling from -60°C to 140°C, 1,500-hour salt-spray tests and 2,500-hour comprehensive endurance runs – with over 9,000 individual test items required for one European premium brand. The company’s CNAS-accredited testing center houses the world’s first 30,000rpm motor test bench.

Manufacturing 

The company operates five smart manufacturing bases across China (Wuxi, Hangzhou, Ningbo, Quzhou, and Jiaxing), with motor line automation reaching 95%. SMT accuracy is held to ±25μm, measurement instruments resolve down to 0.1μm, and an AI-driven visual inspection system detects defects as small as 20μm.

From Wuxi to the world 

InfiMotion produces e-drive systems from 400V to 900V, across a range of vehicle segments, from compact passenger cars to high-performance vehicles. The company operates across China, Europe and Malaysia with vertically integrated capabilities spanning key components through to complete systems. According to InfiMotion, it ranked among China’s top three suppliers by motor and inverter shipments in the first half of 2026, with its production systems supplying manufacturers including Geely, Volvo and JLR.

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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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Mahle says it is accelerating the electrification of road transportation with the upcoming launch of its new range-extender system for heavy electric (BEV) trucks and its Mahle Contactless Transmitter (MCT) electric motor developed for use on the electric drive axles of heavy commercial vehicles.

The company will present its technologies at IAA Transportation, which is to be held in Hannover from September 15 to 20.

Range-extender system

Range extender electric trucks combine the sustainability of electric drive systems with the flexibility and range of the internal combustion engine (ICE). “Time and energy are limited, valuable resources, especially in road transport business; only operators who work economically can survive,” said Arnd Franz, chairman of the group management board and CEO of Mahle. “With electrification products, Mahle can help make heavy trucks more efficient and flexible at the same time as reducing operating expenses.”

The key component of the new system is an efficient high-voltage generator with a continuous output of 110kW and a peak output of up to 130kW, driven by a compact ICE. The high-voltage generator supplies reliable power to the electric drive system even on difficult trips with a full load. Its architecture can be adapted easily to the performance requirements of a variety of applications and regional markets.

Featuring a newly developed advanced oil cooling system, the generator has a power density of more than 7kW per kilogram, allowing a high power output with reduced weight and simplified interfaces.

The system is a self-contained unit integrating a generator, ICE, thermal and fluid management systems, fuel tank, AdBlue tank and exhaust aftertreatment. Designed to fit within the battery installation space of a battery-electric truck, it can be integrated into existing BEV platforms while replacing around one-third of the battery capacity. According to Mahle, this reduces rear axle load by approximately 400kg and overall vehicle weight by around 600kg. The company says the configuration enables a driving range of more than 800km, with roughly half provided by the battery and the remainder by the range extender.

Under real-life operating conditions, the truck emits about 80% less CO₂ in range-extender operation than a truck with a conventional drive system. If the ICE, which is biofuel-ready, is operated with renewable fuels such as the advanced HVO100 bio-diesel, the truck has virtually zero CO₂ emissions.

A comprehensive thermal management system with 48kW of high-temperature and 15kW of low-temperature cooling capacity ensures stable operation of the range extender system under heavy-duty operating conditions. For the ICE engine, Mahle has continued the development of components to reduce fuel consumption and operating costs.

“Our range extender is the key to disconnecting the market ramp-up of battery-electric trucks from the inadequate pace of infrastructure development,” said Dr Marco Warth, the vice president of Mahle Corporate Research and Advanced Engineering. “If the charging station is busy, or alternative routes are called for as a result of weather conditions or congestion, and infrastructure reaches its limits, other fleets can be stranded; an e-truck with range extender just carries on. Operational availability is maintained, even under peak conditions.”

MCT electric motor for heavy commercial vehicles

The MCT electric motor was developed for use on the electric drive axles of heavy commercial vehicles. It is not equipped with permanent magnets and therefore does not require any rare earth elements. Compared with a benchmark permanent magnet synchronous motor (PMSM), the MCT electric motor saves up to 3kg of rare earth magnets per vehicle. The elimination of rare earth magnets reduces the environmental footprint of the electric drive system.

In real-life driving conditions, the new motor is 10% lighter and more efficient than permanently excited electric motors with magnets. Compared with the permanently excited variant, it reportedly offers higher efficiency within a significantly larger operating envelope covering a variety of driving situations. The MCT electric motor has a peak output of 370kW and torque of over 900Nm at 3,900rpm. The motor efficiency in the VECTO cycle, an EU simulation tool for determining the fuel efficiency of new vehicles, is about 95%.

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The smart #2 will have its world premiere at the Paris Motor Show this October and is currently undergoing global testing in preparation. Test vehicles are wearing a black-and-white camouflage livery styled by the Mercedes-Benz Global Design Team.

At dedicated proving grounds, the vehicle’s agility was tested against a wide range of real-world urban challenges, including unexpected obstacles, emergency lane changes and low-grip wet road conditions. According to the auto maker, continuous refinement of the chassis hard points, steering ratio and rack travel and suspension movement control ensures the vehicle remains composed, responsive and agile in everyday city driving.

Extensive noise, vibration, harshness (NVH) validation has been conducted across multiple demanding environments, including the wind tunnel, acoustic chamber, temperature-controlled four-post rig, proving grounds and public roads. The testing activities encompassed wind noise, road noise, powertrain NVH, thermal NVH, squeak and rattle, and sound quality optimization.

By testing various tire compounds on rough asphalt, grooved concrete and high-speed straights, engineers sought an optimal balance between low rolling resistance for maximum range and exceptional noise reduction. To achieve long-term reliability, the vehicle has been subjected to demanding durability testing over bumpy roads, continuous undulations and potholed urban streets. Targeted impact tests simulated common city-driving scenarios, such as mounting curbs and striking deep potholes.

By refining chassis rigidity and structural stress points, the company says it has ensured that the smart #2 will serve as a highly reliable on-road companion. Complementing this structural resilience, the next generation of the renowned Tridion Safety cell – a structural design first used on the original smart fortwo – combines compact exterior dimensions with a robust structure that meets modern safety requirements, providing high protection, stability, and driver confidence.

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Molicel has launched the INR-21700-P70X cell, part of its PX series, to “bridge the gap” between lithium-ion batteries and supercapacitors, the company said. The cell has a stated capacity of 7,000mAh, energy density of 340Wh/kg and continuous discharge rate of up to 30C.

Molicel’s cells have previously been used in performance-focused projects such as the McMurtry Spéirling electric hypercar.

The cell was launched at the Advanced Automotive Battery Conference (AABC) Europe 2026 and comes as BEV growth slows and auto makers increasingly shift investment toward hybrid models. In its 2026 outlook, the International Energy Agency (IEA) highlights this shift, noting that manufacturers are actively prioritizing hybrids. In response, a surge in hybrid demand is redefining key regions: in the USA, hybrids neared 20% of new vehicle sales volume by late 2025 according to CNBC, while in Europe, they captured a 24% market share based on International Council on Clean Transportation (ICCT) data.

Concurrently, the Asia-Pacific region asserted its market dominance, capturing 51.67% of the global hybrid vehicle market value across all segments, including mild, full and plug-in hybrids. The multi-regional momentum is propelling the global hybrid vehicle market from US$335.21bn in 2026 to a projected US$570.78bn by 2034.

This market shift is changing battery requirements for next-generation hybrid vehicles, which demand both high energy density and high power output. According to Molicel, the INR-21700-P70X has been designed to address these requirements, delivering a peak power output of 900W for up to five seconds to support rapid acceleration, such as during overtaking, while also enabling high-power energy recovery under heavy regenerative braking.

The company also states that the cell can transition to high-power output in under 200µs, providing a response comparable to a supercapacitor and supporting repeated high-frequency power pulses with minimal performance degradation.

“The global automotive landscape is undergoing a profound diversification, where the demand for immediate, high-frequency burst power has become paramount,” said Casey Shiue, president of Molicel. “Our next-generation PX series isn’t just an evolutionary upgrade; by blending supercapacitor-like responsiveness with the high energy density of lithium-ion, we are redefining what hybrid powertrains can achieve in terms of raw power, safety and lifespan.”

The INR-21700-P70X has passed the UL9540A thermal runaway evaluation, a widely used safety test for energy storage systems. The company attributes the cell’s performance to its single-crystal cathode technology, which it says reduces exothermic heat generation by nearly 50% compared with conventional polycrystalline materials.

Molicel also stated  that, during abuse testing, the cells emitted smoke rather than undergoing an immediate catastrophic rupture, helping to delay thermal propagation. The company said these characteristics are intended to enhance safety in applications ranging from data center battery backup units (BBUs) to next-generation hybrid electric vehicles (HEVs).

Furthermore, unlike BEVs that undergo deep daily cycles, hybrids subject batteries to hundreds of thousands of rapid, shallow fluctuations. In testing mimicking this environment under a supercapacitor profile, Molicel’s PX series retained 96% capacity after 1,000,000 cycles (+10C for 10s/-2C for 110s, cut-off temperature 83°C).

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