Image: BMW GroupIn the joint research project “Insight,” BMW and its partner have been working together since 2024 to develop practical AI models that optimise battery cell production. The improvements target the entire value chain, from electrode manufacturing and end-of-line testing to in-house-developed direct recycling.The background: At its Battery Cell Competence Center (BCCC) in Munich, the BMW Group develops battery cells for future generations. This work involves numerous test series that require substantial material and time resources. At the same time, these tests tie up production facilities and laboratory capacity.This is where the Insight research project comes into play. “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” BMW explains.As a result, the project could significantly reduce both the duration and the number of test series while maintaining—or even improving—quality. In individual process steps, the newly developed AI systems cut material and time requirements by more than 50%, according to reports.Beyond reducing test series, the predictive models from the research project are also used for the 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,” the partners explain.To achieve these advancements, doctoral students and students from the University of Zagreb have been collecting and structuring existing production data since the project’s launch in 2024. Based on this data, AI models are being developed to identify specific patterns and make predictions that further optimise production in terms of performance, quality, and costs.“We are working on scaling the newly developed AI models from the prototype environment,” said 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.”The University of Zagreb contributes expertise in mechanical engineering, electrical engineering, and computer science to the project. Both partners benefit from continuous knowledge exchange: “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,” the partners state.Another key aspect of the collaboration is the promotion of young talent. “Through this joint project, we inspire doctoral students and students to engage with the fields of AI and battery cells, as well as the exciting activities in our battery cell competence centres,” says Stefan Kerscher, Head of Battery Cell Technology Development at the BMW Group. “We are delighted when young talents choose to start their careers with our company.”BMW has built up extensive in-house expertise in battery cell technology in recent years. As early as 2019, the company opened its Battery Cell Competence Center (BCCC), where it develops new battery cells, produces them on a prototype scale, and tests them.In 2022, BMW expanded these capabilities with the Cell Manufacturing Competence Centre (CMCC) in Parsdorf near Munich. The two facilities work closely together: the BCCC develops the most promising cell concepts, which the CMCC then scales towards series production.In addition to producing prototype cells, BMW is also advancing the reuse of materials. In collaboration with Encory GmbH, the company has commissioned a Cell Recycling Competence Centre (CRCC) in Salching, Lower Bavaria, where it is implementing its direct recycling approach.BMW holds the intellectual property for this recycling method.press.bmwgroup.com