The new hydrogen-powered BMW iX5 with 3D printed parts

The BMW Group starts production of a new car model – the BMW iX5 Hydrogen. The production of the hydrogen-powered vehicle takes place at a plant located at the Munich Research and Innovation Center (FIZ). Numerous components are produced exclusively for this car model, some of which are produced at the Additive Manufacturing Campus, the BMW Group’s center of competence for 3D printing, which was launched in June 2020.

The BMW iX5 Hydrogen goes through all the usual production steps, from the bodyshop, through the paint shop and assembly, to the final inspection of each vehicle. Each vehicle then undergoes a comprehensive performance check at the BMW Group test center in Aschheim.

The BMW iX5 Hydrogen is the first ever Sports Activity Vehicle (SAV) to feature hydrogen fuel cell technology. The car has already undergone an intensive program of testing in demanding conditions during the development phase and will be used as a local emission mobility technology demonstrator in selected regions of Europe from spring 2023.

“Hydrogen is a versatile energy source that has a key role to play in the quest for climate neutrality,” said Frank Weber, Member of the Board of Management of BMW AG responsible for Development. “We are confident that hydrogen will become much more important for individual mobility, so we believe that combining electric drive systems with batteries and fuel cells is a sensible approach in the long term. Fuel cells also do not require any critical raw materials such as cobalt, lithium or nickel, so by investing in this type of powertrain, we are also strengthening the geopolitical resilience of the BMW Group. Our BMW iX5 Hydrogen test fleet will provide us with new and valuable insights that will enable us to present an attractive range of products to our customers when the hydrogen economy becomes a common reality.”

The BMW iX5 Hydrogen is built at the BMW Group’s pilot plant at the Research and Innovation Center in Munich, which employs 900 people. Each of them works on up to six vehicle projects at a time and is tasked with ensuring that both the product and the production process are ready for series production. For the BMW iX5 Hydrogen, specialists in hydrogen technology, vehicle development and model pre-assembly worked closely together to integrate state-of-the-art drive and energy storage technology.

The BMW Group Spartanburg plant in the US supplies the base vehicles for the hydrogen model, which was developed on the BMW X5 platform. They feature a new floor assembly in the body shop of the pilot plant that allows two hydrogen tanks to be placed in the center tunnel and under the rear seat. Model-specific 12V and 400V electrical systems, high-performance battery, electric motor and fuel cell are integrated at the assembly stage along with standard production parts. Located in the area of the rear axle together with the high-performance battery, the electric motor is a product of the current fifth-generation BMW eDrive technology, which is also used in BMW’s battery-powered and plug-in hybrid models. The fuel cell systems under the hood of the BMW iX5 Hydrogen have been produced since August this year at BMW’s in-house hydrogen competence center in Garching, north of Munich.

The BMW iX5 Hydrogen combines all the benefits of a locally emission-free powertrain with outstanding everyday usability and long-haul capability. This makes hydrogen fuel cell technology an attractive, complementary alternative to an electric powertrain. This is especially true for customers who need short refueling stops and long ranges, as well as regions where there is still a lack of adequate charging infrastructure.

Source: www.press.bmwgroup.com
Photos: www.press.bmwgroup.com (press materials / all rights reserved)