BMW Group makes further investment in Plant Landshut

German component manufacturing facility continues its transformation to electric mobility.

BMW Group Plant Landshut is continuing to ramp up production capacity – by expanding the manufacturing facilities for the central housing of the highly integrated electric drive unit to be fitted in Neue Klasse models. The BMW Group is investing a further €200 million to this end, bringing the total channelled into the German factory site since 2020 to around €1 billion.

Of this, some €500 million has been used for the plant’s expansion to cover electric mobility. Annual production capacity for fifth-generation and sixth-generation aluminium housings increases by around 30 per cent. The new model generation will therefore benefit from the know-how of the company’s largest component manufacturing site.

BMW Group Plant Landshut is continuing to ramp up production capacity – by expanding the manufacturing facilities for the central housing of the highly integrated electric drive unit to be fitted in Neue Klasse models

Besides the major expansion of production space in the light metal foundry, the plant is also investing in a state-of-the-art technology for manufacturing its sand cores

“We are continuously expanding our site’s expertise in both the production of our cutting-edge components and the development of new technologies,” says Thomas Thym, Head of BMW Group Plant Landshut. “This skill set provides us with the flexibility we are going to need in the future.” Manufacturing the central housing for the sixth-generation drive technology in the Neue Klasse represents a further step in the plant’s transformation to electric mobility.

A brand new production hall is currently being built that will be spread over three levels. In future, production will take place here on two production lines covering an area of 12 000 square metres using the pioneering injector casting process. Injector casting ensures that parts are cast with optimum mechanical properties. It has the additional effect of shortening the cycle time and, as a result, reducing energy consumption considerably while also cutting carbon emissions due to the lower casting temperature. This method results in reduced consumption of resources too as it requires less return material.

In January of this year, the BMW Group purchased a plot of land directly adjacent to Plant Landshut that is about 30 000 square metres in size and has been earmarked for further expansion of production in the future. This strategic acquisition is a key element in the plant’s ability to respond to future demand. A final decision on how exactly the new land is to be used will be made at a later date.

These sand cores are deployed in six different cylinder head variants for production of BMW engines worldwide

In 2023, BMW Group Plant Landshut produced a total of around 3.6 million cast components

3D printing technology for large-scale production of complex sand cores
Besides the major expansion of production space in the light metal foundry, the plant is also investing in a state-of-the-art technology for manufacturing its sand cores. These sand cores are deployed in six different cylinder head variants for production of BMW engines worldwide. The plant makes up to 4 500 units on 17 printers daily in a large-scale 3D printing process. The sand cores are moulded by printing them layer by layer on a print head system using emission-free and environment-friendly inorganic binders.

Ongoing training programme forms backbone for transformation
A broad-based training initiative is being put in place to accompany the site’s gradual transformation. In order to meet future technological needs, the plant is focusing primarily on skills in the areas of robotics, quality and process management, electrical and electronic analysis, maintenance and logistics.

The site in Lower Bavaria continues to manufacture propeller shafts, crankcases, cylinder heads and engines on a demand-driven basis for the efficient ICE models in the product portfolio

BMW Group Plant Landshut is pioneering the injector casting process. Injector casting ensures that parts are cast with optimum mechanical properties. It has the additional effect of shortening the cycle time and, as a result, reducing energy consumption considerably while also cutting carbon emissions due to the lower casting temperature. This method results in reduced consumption of resources too as it requires less return material

Production volumes last year
As well as manufacturing components for the company’s all-electric models, Plant Landshut also stands out with its highly flexible production system. The site in Lower Bavaria continues to manufacture propeller shafts, crankcases, cylinder heads and engines on a demand-driven basis for the efficient ICE models in the product portfolio.

In 2023, BMW Group Plant Landshut produced a total of around 3.6 million cast components.