AESC has begun mass production of its new 46120 cylindrical cells, a component that will mark a turning point for BMW's electric vehicle range . This move means that large-format battery technology is no longer a prototype, but an industrial reality ready to equip the German brand's upcoming models.
The first car to benefit from these batteries will be the BMW iX5, an SUV that will be assembled at the Spartanburg plant in the United States. Although the model retains the CLAR platform, it incorporates the sixth-generation eDrive system and an 800-volt architecture , promising faster charging and a range that could exceed 600 kilometers, according to industry estimates.
The new 46120 cells: more energy, fewer components
The cells measure 46 millimeters in diameter and 120 millimeters in height, and offer an energy density of up to 310 Wh/kg. According to AESC, the usable energy per cell has increased by almost 30% compared to previous prismatic formats , allowing for a reduction in the number of cells required in the pack and simplifying integration into the chassis. The cathode uses a nickel-rich composition, while the anode is doped with silicon, a combination that improves both capacity and thermal stability.
The BMW iX5 debuts the sixth generation eDrive
BMW has confirmed that the iX5 will be equipped with a 141 kWh battery and will operate at 800 volts. This translates to shorter charging times and greater energy density compared to the previous generation of prismatic cells . Although the SUV does not use the future Neue Klasse architecture, it does feature the Bavarian automaker's most advanced battery technology. The commercial launch is planned for late 2026 or early 2027.
Precision manufacturing: X-ray inspection and magnetic levitation
AESC's production process is almost surgical. Each assembly line has more than 1.000 inspection stations equipped with cameras, and all cells undergo complete X-ray inspection . Furthermore, internal material transport is carried out using a magnetic levitation system that guarantees a manufacturing accuracy of 0,01 millimeters. David Wan, AESC's global CEO, emphasized that years of R&D and automation have made it possible to scale production without sacrificing quality.
Where are they manufactured? The mystery of the plant
AESC has not revealed which specific facility has started mass production. The company has factories in China, Japan, the United States, the United Kingdom, France, and Spain. In 2022, it announced a plant in South Carolina to supply BMW, but the project was suspended in mid-2025 , so it's unclear whether the iX5's cells will come from there or another location. The only certainty is that manufacturing is already underway at its state-of-the-art facilities.
With these batteries, AESC and BMW aim to make a significant leap forward in the electric vehicle market. The combination of higher energy density, fewer components, and ultra-precise manufacturing suggests that the iX5 will be one of the most advanced SUVs in its segment, although we will have to wait for official range figures to confirm whether it lives up to expectations.