AESC launches mass production of new 46120 cylindrical cells for the BMW iX5
The new battery cell measures 46mm in diameter and 120mm in height, representing AESC’s latest breakthrough in large-format cylindrical cell technology. Compared to previous cell formats, the usable energy per cell has increased by nearly 30 per cent. At the same time, the number of cells and components required in the battery pack has been reduced, simplifying system integration and providing greater flexibility in vehicle design. For the cathode, AESC uses a nickel-rich chemistry, while the anode is silicon-doped. The company reports an energy density of up to 310Wh/kg. Additionally, optimised thermal management and structural enhancements are expected to improve the safety and long-term stability of the batteries.
According to AESC, production incorporates over 1,000 camera-based inspection stations along the manufacturing line, as well as full X-ray inspection for every individual battery cell. The production process is further enhanced by a magnetic levitation system for material transport, which enables manufacturing precision of up to 0.01 millimetres. “Years of R&D and manufacturing expertise have enabled the mass production and global rollout of our 46120 cells,” explained David Wan, Global CEO of AESC.
With the start of production, AESC is laying the foundation for the ramp-up of BMW’s next-generation batteries. The first vehicle announced to feature the new cylindrical cells is the all-electric BMW iX5, which will be produced at BMW’s US plant in Spartanburg. Although the SUV is still based on the CLAR platform rather than the Neue Klasse architecture, it already incorporates the battery technology of BMW’s sixth-generation eDrive system. The iX5 will enter the market with a 141 kWh (net) battery and an 800-volt architecture. BMW expects the large-format cylindrical cells to deliver higher energy density, shorter charging times, and greater range compared to the previous prismatic cell generation.
AESC has not specified at which plant mass production of the large cells has commenced. The company states only that “mass production has begun at AESC’s state-of-the-art manufacturing sites.” AESC builds or operates production facilities in China, Japan, the United States, the United Kingdom, France, and Spain. To supply BMW in the US, AESC announced the construction of a new plant in Florence County, South Carolina, following a major order placed in 2022, but paused the project in mid-2025. It remains unclear whether the cylindrical cells for the iX5 will be supplied from this plant or another location.
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