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The electric vehicle landscape is witnessing a significant power shift. BMW's decisive move toward large cylindrical batteries marks a pivotal moment, promising revolutionary charging speeds and reshaping the competitive dynamics of the battery technology arena. As industry giants like Tesla and BMW champion this format, large cylindrical cells are emerging from the shadows of technical debate, poised to redefine the future of EV power solutions.
This transition represents more than just a technical choice; it's a complex balancing act between peak battery performance and cost efficiency, demanding unprecedented levels of supply chain innovation.
February 2024 saw BMW Group unveil its sixth-generation electric drive system, with the headline-grabbing announcement being the mass production plan for its large cylindrical battery technology. Within the realm of EV battery formats – primarily dominated by prismatic, pouch, and cylindrical cells – prismatic has long reigned supreme. Recent data shows prismatic cells commanded a staggering 96.7% of the Chinese market in 2024, leaving cylindrical batteries with a mere 2% share.
While Tesla ignited mainstream interest with its 4680 large cylindrical cell reveal in 2020, BMW's endorsement signals a major acceleration. The core appeal lies in transformative performance: integrated with an 800V high-voltage platform, BMW's large cylindrical batteries enable drivers to add an impressive 300 kilometers of range in just 10 minutes of charging, dramatically enhancing the EV user experience.
Engineered under the principle of "thinner battery packs, faster charging, longer range," these cells deliver substantial gains: a 20% boost in battery energy density, a 30% increase in driving range, and a 30% improvement in fast charging capability. This compelling combination makes them an increasingly attractive option for automakers.
BMW's pivot is particularly noteworthy. Having relied on prismatic batteries for its first five EV generations, this strategic shift to large cylindrical cells is fundamentally driven by evolving customer demands for EVs. As BMW Group Board Member Frank Weber emphasized during a Munich briefing, "The large cylindrical cell isn't a universal solution, but it represents the integrated best solution based on the specific needs of BMW customers."
BMW's commitment to delivering a dynamic, sporty driving experience necessitates a battery capable of rapid energy discharge, coupled with high energy density, durability, and stable, predictable cycle life. For these specific requirements, large cylindrical technology currently presents the "optimal solution."
However, scaling production presents a formidable hurdle. Tesla's journey with the 4680 has been fraught with challenges, largely attributed to its ambitious pursuit of dry electrode processing – a technique promising significant battery cost reduction but proving difficult to master at scale. BMW, learning from this, is adopting the more established wet process. Yet, significant manufacturing complexities remain, particularly concerning tab cutting, folding, and welding. The path to large cylindrical battery mass production is still demanding.
BMW's strategy for its sixth-generation battery is explicitly global. Frank Weber stated, "Our sixth-generation battery has a more global approach. We build production facilities together with partners in China, Europe, and the US." Key to this plan are BMW's established Chinese battery partners.
The automaker has confirmed that CATL (Contemporary Amperex Technology Co. Limited) and EVE Energy will supply large cylindrical cells for BMW's EVs in China and Europe. Both companies are constructing dedicated local factories in these regions to meet BMW's needs. For the crucial North American market, AESC Envision stands as the sole designated supplier.
The BMW CATL partnership has deep roots, originating in 2012 when BMW selected the then-emerging CATL to supply batteries for its Zinoro 1E electric SUV. This pivotal collaboration propelled CATL's rise to become the global leader known as the "King of Batteries."
EVE Energy carved its path into BMW's supply chain through early and unwavering commitment to large cylindrical battery development. This foresight positioned EVE perfectly when BMW solidified its large cylindrical strategy in 2022, elevating the Chinese firm to a position as one of BMW's most critical battery technology partners.
AESC Envision, tracing its lineage back to the 2007 Nissan-NEC joint venture (the world's first mass producer of automotive lithium-ion batteries), brings immense heritage. Acquired by China's Envision Group in 2019, AESC Envision boasts 13 global manufacturing sites and batteries powering over a million EVs. Crucially, AESC has operated in the US for over a decade, with its Tennessee plant commencing production in 2012 and recently adding an energy storage line. This extensive US manufacturing experience and proven market adaptability made AESC Envision the ideal choice for BMW's North American requirements.
Following a confirmed order in October 2022, AESC Envision has already commenced deliveries of its 46-series large cylindrical batteries from its massive factory in Jiangyin, Wuxi. Initial shipments are destined for the US to support BMW's sixth-generation global EV platform.
BMW has long been an automotive industry trendsetter. Its strong endorsement of large cylindrical batteries significantly accelerates the format's adoption, profoundly impacting the existing battery market structure.
On the manufacturing front, the large cylindrical camp now boasts formidable supporters: CATL, AESC Envision, CALB (China Aviation Lithium Battery), EVE Energy, Panasonic, Samsung SDI, and even hints from BYD in 2023 suggest potential entry. Vehicle integration momentum is equally strong, with Tesla, BMW, Volvo, Porsche, and NIO publicly committing to adopting large cylindrical battery technology.
Liu Jincheng, Chairman of EVE Energy, confidently stated, "Large cylindrical batteries will become the main power solution for future mid-to-high-end vehicles." Major research firms project global demand for large cylindrical cells will surge to hundreds of GWh by 2025. Forecasts suggest the market size in 2030 could be 4-5 times larger than 2025 levels, representing a vast, untapped opportunity.
This burgeoning potential is triggering aggressive strategic moves from automakers and suppliers alike, setting the stage for the next intense battery technology competition. Nevertheless, significant challenges remain. Achieving competitive battery manufacturing costs, alongside navigating the emergence of disruptive technologies like solid-state batteries and semi-solid-state batteries, will be critical tests for suppliers in the coming years.
BMW's decisive entry into the large cylindrical battery arena sets a powerful new technical benchmark for the industry. It strongly signals the accelerated arrival of the "cylindrical era" in electric vehicle power systems.
The ultimate success and widespread adoption of this technology, however, hinge on two critical factors: achieving seamless industry collaboration across the complex supply chain, and mastering the delicate art of finding the perfect "golden balance point" between uncompromising battery performance and economically viable production costs. As this transformation unfolds, a dynamic new battery supplier landscape is rapidly taking shape, poised to power the next generation of electric mobility.
Edit by paco
Last Update:2025-07-17 10:52:09
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