SHANGHAI / MUNICH – Envision AESC has started mass production of its advanced 46120 large-format cylindrical battery cells at its super factories in Cangzhou and Jiangyin, China. This marks a key step in the company’s global supply agreement with BMW Group, as the cells will power several models on BMW’s “New Class” electric vehicle platform for worldwide deliveries.
BMW recently unveiled the all-electric iX5, the first production model to adopt Envision AESC’s 46120 cells (46 mm diameter, 120 mm height). Compared with the 4695 cylindrical cells (46 mm × 95 mm) used in the earlier iX3, the new 46120 format delivers about 30% more usable energy per cell, significantly boosting pack-level energy density without increasing the overall footprint.
The 46120 cell now in production is currently the tallest and highest-capacity 46-series cylindrical battery cell in mass production worldwide. Surpassing the industry’s mainstream 4680 and 4695 formats, its larger individual capacity allows automakers to reduce both the total number of cells and structural components in the pack. This simplifies system integration, improves efficiency, and frees up more interior space—an important advantage for premium SUVs balancing range, performance, and passenger comfort.
High-Nickel Chemistry and Precision Manufacturing
Cell chemistry features a high-nickel cathode paired with a silicon-doped anode. The design achieves a gravimetric energy density of more than 310 Wh/kg. Safety innovations such as thermo-mechanical separation at the cell and pack levels provide system-level crash protection and thermal runaway prevention. According to Envision AESC, the solution delivers a balanced triad of performance, safety, and cost-efficiency tailored for high-end battery electric vehicles.
Ultra-Low Defect Rate and Micron-Level Accuracy
On the manufacturing side, Envision AESC has deployed over 1,000 CCD vision inspection stations and 100% X-ray scanning for foreign-particle detection throughout production, enabling micron-level contamination control. A maglev high-speed positioning and transfer system works alongside precision winding and assembly processes to maintain dimensional accuracy within 0.01 mm. Internal quality data shows the overall production yield rate ranks among the best in the industry, with a field failure rate projected at less than one in ten billion.
Global Footprint and Customer Trust
“The mass production and global delivery of our 46120 large cylindrical battery is the culmination of years of R&D and manufacturing expertise at Envision AESC,” said Biao Wan, Global CEO of Envision AESC. “It also reflects the trust that premium customers place in our product performance, quality systems, and scale-up capabilities. Leveraging our smart manufacturing platforms and high-quality output, we are committed to helping global automakers build even more competitive next-generation electric vehicles.”
To support its growing international customer base, Envision AESC continues to expand localized production. The company now operates gigafactories in China, Japan, the United States, the United Kingdom, France, and Spain, forming a resilient supply network that covers all major automotive markets. This global footprint ensures both supply security and regional responsiveness for automakers launching products across continents.
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