The BMW Group has achieved a 50 percent reduction in battery cell testing time through a pilot project at its Battery Cell Competence Centre in Munich, leveraging artificial intelligence developed in collaboration with the Regional Centre of Excellence for Robotic Technology (CRTA) at the University of Zagreb. This advance extends beyond testing to encompass the entire battery cell value chain, from electrode production through in-house direct recycling, demonstrating a commitment to sustainable manufacturing. The AI network analyzes existing and real-time production data to predict battery cell performance, reducing material and time investment while maintaining quality. “We are working on scaling the newly developed AI models from the prototype environment,” explains Christian Siedelhofer, head of Technology Development Lithium-Ion Battery Cells at the BMW Group, potentially optimizing production and eliminating quarantine phases for newly produced cells.
AI-Driven Optimization of BMW Battery Cell Production
This efficiency gain represents a significant step toward resource conservation and cost reduction in the electric vehicle market. The optimization relies on an artificial intelligence network that leverages historical test data and real-time production information to predict key battery cell parameters and performance characteristics. This predictive capability allows BMW to reduce the length and quantity of physical test series without compromising, and potentially improving, product quality. The AI systems are also being explored to eliminate the “quarantine” phase, the period of storage at precise temperatures following initial charging, by providing a comprehensive pre-approval analysis of each cell. This collaboration is mutually beneficial; the University of Zagreb contributes expertise in mechanical, electrical, and computer engineering while providing a practical application for its doctoral candidates and students, strengthening the innovation capabilities of both institutions and positioning them for continued advancements in battery technology and sustainable manufacturing practices.
University of Zagreb & BMW “Insight” Research Project
Initiated in 2024, this “Insight” research project extends beyond quality control to encompass electrode production and BMW’s in-house direct recycling processes, supporting a fully closed-loop manufacturing system. Doctoral candidates and students at the University of Zagreb are central to this effort, collecting and structuring production data to create predictive AI models. The AI network analyzes existing test data alongside real-time production information to forecast battery cell performance with increasing accuracy.
Our joint project gets doctoral candidates and students interested in AI and battery cells and the exciting work we do at our Battery Cell Competence Centres.
Stefan Kerscher, head of Technology Development Battery Cells at the BMW Group
50% Reduction in Testing & Material Usage
Initial results indicate a greater than 50 percent reduction in the material and time required for individual process steps, achieved through predictive AI models. This predictive capability extends beyond standard testing parameters, potentially eliminating the “quarantine” phase currently required for final battery cell approval. Following initial charging, cells typically undergo a period of storage at controlled temperatures before housing installation; the AI systems aim to bypass this step through comprehensive pre-analysis. Siedelhofer adds, “One option would be to enable cell manufacturers,” suggesting ambitions beyond internal optimization. The partnership also prioritizes talent development, offering students practical experience and bolstering the industry’s AI expertise, ultimately strengthening the innovation capability of both organizations.
Battery Cell Competence Centre & Recycling Innovations
The BMW Group is integrating artificial intelligence throughout its battery cell production, extending beyond testing efficiencies to encompass the entire lifecycle, from electrode creation to in-house direct recycling. Unlike isolated improvements, the project focuses on the complete battery cell value chain, promising a closed-loop manufacturing system. The AI systems are not solely accelerating testing; they are also impacting storage requirements. The company explains, “Following initial charging at the end of production, the cells must be stored for a defined period at precisely specified temperatures before they can be installed in a battery housing,” but the AI is capable of analyzing cells in advance, potentially eliminating this “quarantine” phase altogether.
We are working on scaling the newly developed AI models from the prototype environment.
Christian Siedelhofer, head of Technology Development Lithium-Ion Battery Cells at the BMW Group
