i3 countdown
BMW starts pre-series production of the new i3 at the Munich plant
With the first pre-series vehicles of the new i3, the final phase before the series launch of the Neue Klasse begins at BMW's Munich headquarters in the second half of 2026.
As the saying goes, one should not praise the day before the evening, but so far things are going well for BMW. The launch of the first model of the Neue Klasse, the iX3, is in full swing. And now, at the Munich plant, pre-series production of the new i3 has begun. For the first time, almost production-ready vehicles are being created there, going through all production steps at the plant. This marks the start of the final preparation phase for series production in the second half of 2026.
Even though the quantities are still low at this stage, all logistics processes, systems, and work steps must already function under real conditions. Every component is brought to the line via the intended material flows, and every process step is checked and fine-tuned. The goal is to identify potential weaknesses early and stabilise the processes before ramp-up.
For the Munich plant, this step marks a significant turning point. As recently as 2024, the site was characterised by massive reconstruction work. While around 1,000 vehicles were produced daily, new buildings were erected, old production areas were dismantled, and logistics routes were reorganised. Demolition, new construction, and series production ran in parallel in a confined space. The fact that complete vehicles of the Neue Klasse can now be manufactured at the plant is a visible signal that the extensive reconstruction processes have reached the decisive phase.
The now almost production-ready manufacturing shows that our logistics and production processes work under real conditions.
Stress test for new production structures
The pre-series run is the first time all modernised production and logistics areas are tested together. This includes the modernised press shop, the newly built body shop, the paint shop, as well as new assembly and logistics structures. All parts are already provided and processed via the final intended material flows. A particular focus is on the approval testing of the new production facilities and tools, as well as their digital connection to existing systems. The insights gained from this test operation are intended to be used to further refine processes and ensure a stable series start.
In parallel, intensive qualification measures for the workforce are underway. Employees are initially trained virtually, including with augmented reality applications, and then directly on the new facilities. The close cooperation of all production areas is intended to ensure that all processes interlock during the series start-up and that interfaces between production, logistics, and maintenance function stably.
Second series model of the New Class
The new i3 is the second series vehicle of BMW's New Class. The iX3 was the first, produced at the new Hungarian greenfield plant in Debrecen. Demand for the electric SUV is currently so high that a second shift has already been commissioned. The experiences from the ramp-up in Debrecen are also being incorporated into the preparation of Munich production, particularly in start-up control, qualification, and process assurance.
For BMW, however, the i3 has a special strategic significance. The 3 Series has been one of the brand's most important and iconic models for decades. Hardly any other vehicle stands so strongly for volume, profit, and brand identity. Accordingly, expectations for the electric reinterpretation of the saloon and how it will be received by customers are high. The fact that the pre-series run is now starting as planned is likely to be closely monitored both internally and externally.
Key role for the main plant
For the main plant in the Bavarian capital, the i3 launch also takes on a structural dimension. The site currently produces several models and types of drive on one line, including combustion engines, plug-in hybrids, and fully electric vehicles. With the Neue Klasse, complexity initially increases further before it is reduced again in the medium term. The i3 serves as a reference model on which material flows, cycle times, and the new high-rise logic are tested under volume conditions. If this ramp-up succeeds as planned, it is likely to be decisive in determining how quickly and stably further models of the Neue Klasse can be integrated into existing brownfield structures.
