BMW begins pre-series production of new i3 at Munich plant

BMW Group has begun producing pre-series vehicles for the new BMW i3 at its Munich assembly plant, marking a key step toward series production scheduled to begin in the second half of 2026. The move signals that the facility has transitioned from preparation and pilot phases into near-series manufacturing conditions, with vehicles now moving through all major production stages on site.

Pre-series production is a standard phase in automotive manufacturing, used to validate production processes, logistics flows, tooling, and quality systems before full-scale manufacturing begins. While volumes remain limited, the vehicles are assembled using production-intent equipment and processes rather than prototype or experimental setups. According to BMW Group, the pre-series i3 vehicles built in Munich are intended to replicate series production conditions as closely as possible, allowing the company to identify and resolve issues ahead of the official production launch.

The Munich plant occupies a central role in BMW Group’s broader manufacturing network and has undergone significant modernization in preparation for the new model. The facility now includes a reworked press shop, a newly constructed body shop, an updated paint shop, and a redesigned assembly area, all of which are being exercised during the pre-series phase. BMW says this is the first time the new i3 has been built entirely at the Munich plant, rather than split between multiple facilities or pilot lines.

Earlier pre-production vehicles were assembled with involvement from BMW’s nearby pilot plant at the company’s Research and Innovation Centre. Pilot plants are typically used to validate vehicle designs and early manufacturing concepts before production tooling is installed at full-scale plants. With the completion of Munich’s new production and logistics areas, the manufacturing process has now been consolidated entirely within the main plant, allowing BMW to test the complete production chain under real-world conditions.

During this phase, all components are delivered using the same logistics routes and material flows planned for series production. Even though output remains limited, parts are handled, staged, and installed using production-standard systems. This allows BMW to evaluate how materials move through the facility, how workstations function under normal operating conditions, and how well different production systems interact with one another. Each production step is closely monitored to ensure that equipment performance, quality targets, and timing requirements are being met.

A significant focus of the current phase is the approval and validation of new production equipment and tooling. BMW Group notes that particular attention is being paid to how new machinery is digitally integrated with existing manufacturing systems. Modern automotive plants rely heavily on interconnected digital systems to manage everything from component tracking to quality control and maintenance planning. Ensuring compatibility and stability across these systems is a critical requirement before series production can begin.

BMW also emphasized that insights gathered during pre-series production will be used to further refine processes in the coming months. This includes identifying inefficiencies, adjusting workflows, and fine-tuning equipment settings. The goal is to ensure that series production can begin without major disruptions once volume ramps up. While BMW did not provide details on production capacity or expected output levels for the i3 at Munich, the company characterized the current phase as the final preparation stage ahead of series launch.

Employee training is another major component of the pre-series phase. BMW Group stated that workers initially trained using virtual and augmented reality tools before transitioning to hands-on instruction on the actual production equipment. This approach is increasingly common in modern automotive plants, as it allows employees to familiarize themselves with processes and layouts before physical systems are fully operational. Training across departments is intended to ensure that production, logistics, and quality teams are aligned once series production begins.

The Munich plant’s transition to pre-series production reflects broader changes underway within BMW Group’s manufacturing strategy. As the company continues to expand its lineup of electric vehicles, existing plants are being reconfigured to accommodate new platforms, powertrain architectures, and assembly requirements. This often involves integrating electric vehicle production alongside internal combustion models or transitioning facilities entirely to new vehicle types, depending on long-term product plans.

BMW has not released technical specifications, performance figures, or efficiency data for the new i3 at this stage, noting that the vehicles currently being built are pre-production models. As such, fuel consumption or energy use figures are not available. This is consistent with industry practice, as final certification and testing typically occur closer to the start of series production.

The company also did not disclose details about the vehicle’s underlying platform, battery configuration, or market positioning in this announcement. The focus of the release was squarely on manufacturing readiness rather than product characteristics. Additional information is expected closer to the start of series production or during official product presentations.

BMW Group’s Munich plant is one of more than 30 production sites operated by the company worldwide. The group manufactures vehicles under the BMW, MINI, Rolls-Royce, and BMW Motorrad brands and maintains a global sales presence in over 140 countries. In 2024, BMW Group reported global sales of 2.45 million passenger vehicles and more than 210,000 motorcycles, with revenues totaling €142.4 billion and a workforce of just over 159,000 employees as of the end of that year.

From an industry perspective, the move into pre-series production is a critical milestone that typically precedes final regulatory approvals, supplier ramp-up, and full workforce deployment. Any issues uncovered at this stage are generally less costly to resolve than problems discovered after series production begins. For manufacturers introducing new vehicle architectures or significantly updated production processes, the pre-series phase often plays a decisive role in ensuring launch quality and production stability.

BMW indicated that the Munich plant will continue refining processes throughout the coming months, using data and experience gained from the initial pre-series vehicles. The company described this period as essential for ensuring a smooth transition into series production in the second half of 2026. No further changes to the production timeline were announced.

For now, the start of pre-series production represents a procedural step rather than a market-facing event. While the vehicles themselves remain out of public view, the shift signals that BMW’s manufacturing preparations for the new i3 have moved beyond planning and pilot testing and into operational execution under production conditions.