BMW’s Neue Klasse Gains a 1,700-Robot Production Backbone

ABB Robotics announced on November 11, 2026, that it is supplying more than 1,700 large industrial robots for BMW Group’s Neue Klasse vehicle generation. The deployment covers body-shop production at BMW plants in Munich, Germany, and Tiexi, China, where the machines will handle welding, gluing, riveting and assembly.

Munich’s robot installation includes production of the new fully electric Neue Klasse models. ABB presents the project as a move toward higher efficiency, greater precision and more sustainable production, with every robot using the latest generation of ABB’s OmniCore controller.

“Our collaboration with the BMW Group underscores a shared vision of flexible and future-proof production,” Joerg Reger said. Reger connected the robot and control package with manufacturing digitalization, precision, efficiency and energy savings.

Three robot families for body-shop work

The delivery spans three large-robot families: the IRB 6720, IRB 6740 and IRB 7720. ABB product documentation lists different strengths across the range, with the highest payload and longest reach belonging to different variants.

• IRB 6720: maximum payload of 240 kg and maximum reach of 3.2 m. ABB lists high-precision body assembly, spot welding and gluing among its uses.
• IRB 6740: maximum payload of 310 kg and maximum reach of 3.2 m.
• IRB 7720: maximum payload of 620 kg and maximum reach of 3.5 m. It covers high-payload assembly and handling, electric-vehicle batteries, press tending and friction stir welding.

These figures are product specifications, not reported BMW production results. For repetitive welding and assembly, they describe the intended combination of precise path following and high-speed movement. ABB reports path accuracy down to 0.6 millimeters at speeds up to 1,600 millimeters per second for OmniCore-controlled robots.

Standardized components run across ABB’s large-robot platforms. The IRB 7720 shares its modular design and footprint with the IRB 67X0 family, which ABB says enables faster, more flexible installation when robots change on production lines. For BMW’s two-plant deployment, that creates a common mechanical basis for line changes alongside the shared control system.

One controller across the deployment

OmniCore acts as a unified system for motion, force and sensor applications. ABB describes it as combining integrated sensor and AI processing with connectivity and cybersecurity, while also supporting cloud and edge technologies. That gives the deployment an AI and sensor-integration layer alongside its motion control.

Integrated communication protocols and pre-engineered software can shorten commissioning from weeks to days, according to ABB. OmniCore’s regeneration technology returns power to the grid and carries an ABB rating of up to 20% energy savings compared with its predecessor. For the IRB 7720, the combined robot-and-controller design is rated for an energy reduction of up to 30%.

Those percentages describe different product scopes, not one combined saving across BMW’s robot fleet. That distinction matters because the 1,700-plus machines cover different robot families and tasks across two plants.

A wider technology picture for BMW’s electric vehicles

The robot announcement sits alongside other developments tied to robotics, batteries and vehicle production. ZJK Industrial Co., Ltd. established a core precision component portfolio with six product series for the robotics industry: precision gear transmission components, precision linear motion components, precision transmission connectors, robotic body load-bearing components, specialty fasteners for robotic arms and robotic elastic components.

Lumissil Microsystems and BMW Group also demonstrated Power Line Communication technology across a complete BMW Gen6 800 V battery system. The demonstration marked a milestone toward simpler, lighter and more scalable Battery Management System architectures for future electric vehicles.

The joint work uses a “No New Wire” approach, allowing communication between the central BMS controller and Cell Supervisory Circuits through the battery’s existing electrical infrastructure. It removes the need for dedicated communication wiring for the PLC network.

BMW has also signed agreements with Samsung SDI and LG Energy Solution for high-voltage battery cells. Samsung SDI will supply cells produced at its European facilities, while LG Energy Solution will supply cells manufactured in the United States. Deliveries are expected to begin in the late 2020s.

“Diversifying procurement is an integral part of the BMW Group’s purchasing strategy,” Nicolai Martin said. “We aim to ensure our products’ global competitiveness and to be successful in different markets.” Martin added that BMW operates as locally as possible in its value chains while using the potential of global procurement markets.

Hendrik Lang said cooperation with leading battery cell manufacturers helps BMW maintain supply security and competitiveness. “Our global partner network with leading cell manufacturers ensures that we have a resilient, flexible and competitive battery cell supply,” Lang said.

Automechanika Shanghai 2026 will take place at the National Exhibition and Convention Center (Shanghai) from 2 to 5 December 2026. The event will occupy the entire venue, including 390,000 sqm across 16 halls and the mezzanine floor.

For the Neue Klasse body shops, the central message is straightforward: BMW is pairing a large robot fleet with a shared control platform, standardized mechanical components and production systems designed for electric vehicles. The result is a manufacturing setup built around precision, line flexibility and energy management.

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