Munich/Zagreb. The BMW Group and the Croatian
University of Zagreb’s Regional Centre of Excellence for Robotic
Technology (CRTA) continue to advance joint research in battery cell
production. The “Insight” research project will develop and implement
practical AI models to optimise battery cell production at the BMW
Group. The research project covers the entire battery cell value
chain: from electrode production to end-of-line testing and in-house
developed direct recycling.

How the research project saves raw materials, costs and time

At the Battery Cell Competence Centre (BCCC) in Munich, the BMW Group
is developing battery cells for future generations of high-voltage
batteries. As part of this process, numerous test series are
conducted, which by their very nature require significant time and
material investment. At the same time, these tests tie up
manufacturing equipment and laboratory capacity. This is where the
“Insight” research project comes in: Its artificial intelligence
network uses existing test data, as well as real-time data from
ongoing production, to accurately predict battery cell process
parameters and performance data. As a result, the duration and number
of test series can be significantly reduced, while maintaining or
improving quality. In this way, the newly developed AI systems reduce
the material and time required in individual process steps by more
than 50 percent.

Other cell production use cases

The research project’s prediction models not only reduce the number
of test series but also support final approval of battery cells.
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. This phase, also referred
to as the “quarantine”, requires corresponding storage capacity.
However, the research project’s AI systems are able to conduct a full
analysis of the battery cells in advance, potentially eliminating this
process step in the future.

Research collaboration combines theory and practice

Since the project was launched in 2024, the BMW Group and the
University of Zagreb have been developing joint solutions using
artificial intelligence to improve battery cell production. To this
end, doctoral candidates and students at the University of Zagreb are
collating and structuring available production data and using it to
create AI models that can identify specific patterns. These AI models
then make predictions that further optimise production performance,
quality and costs. “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. One option would be to enable cell manufacturers.
“We are also examining to what extent these models are suitable for
additional use cases within our production network.”

Win-win through knowledge sharing

The University of Zagreb contributes expertise in mechanical
engineering, electrical engineering and computer science to the
project. Ongoing knowledge sharing benefits both partners: The
University of Zagreb provides the BMW Group with access to the latest
research findings, while its doctoral candidates and students have the
opportunity to apply their theoretical knowledge in practice.

Development of young talent

Another aspect of the cooperation is the development of young talent.
“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,” says Stefan Kerscher, head of Technology
Development Battery Cells at the BMW Group. “We are delighted when
young talents decide to embark on a career with our company.” The
cooperation offers students intensive mentoring and the opportunity to
expand their professional network across the industry, enhancing their
attractiveness on the job market and opening up outstanding career
opportunities. The cooperation between the BMW Group and the
University of Zagreb strengthens the innovation capability and
competitiveness of both partners.

Battery cell expertise along the entire value chain

The BMW Group consolidates its battery cell know-how at its
Competence Centres in Munich, Parsdorf and Salching. The Battery Cell
Competence Centre (BCCC) in Munich houses research and development for
the battery cells of the future. The best battery concept from the
BCCC will be produced under near-series conditions at the Cell
Manufacturing Competence Centre (CMCC) in Parsdorf. Close
cross-divisional collaboration between Development, Purchasing and
Production integrates product and process in a unique way. In addition
to producing sample cells, the BMW Group is also focusing its efforts
on the reuse of materials. As part of this process, the company has
put into service a Cell Recycling Competence Centre (CRCC) in
Salching, Lower Bavaria, together with Encory GmbH, which will
implement the innovative direct recycling concept. The intellectual
property for the recycling method is owned by the BMW Group.