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The "Invisible Car" Becomes Real: Munich Prepares for the BMW Neue Klasse i3

The heart of BMW’s manufacturing empire, Plant Munich, has officially transitioned from digital theory to physical reality. For months, engineers have been conducting "Common Function Tests," a high-stakes dress rehearsal where the entire production line runs at full speed, assembling an "invisible car." While no actual parts were used during those initial phases, the exercise allowed technicians to validate every robotic arm and digital interface in a perfect, high-precision stress test.

Today, the "invisible car" is a thing of the past. As of February 2026, the first complete pre-series BMW i3 vehicles are officially rolling off the production line. This marks the final preparation phase before full-scale series production begins in the second half of the year, signaling that BMW’s home plant is ready to lead the charge into the "Neue Klasse" era.

A Logistical Marvel: Rebuilding One-Third of the Plant

What makes this milestone even more impressive is the environment in which it was achieved. Over the past 18 months, BMW has pulled off a logistical feat that many industry experts deemed impossible: they completely reorganized one-third of the plant’s footprint without stopping production for a single day.

While old halls were dismantled to make way for a state-of-the-art body shop and assembly halls, the facility continued to manufacture up to 1,000 BMW 3 Series and 4 Series vehicles every workday. This "open-heart surgery" on the factory floor ensured that BMW met current customer demand while simultaneously building the infrastructure for the most advanced electric vehicles in the brand’s history.

BMW iFACTORY: Virtual Success Before the First Bolt is Turned

The seamless transition to the i3 is the result of BMW’s "iFACTORY" strategy; a digital-first approach to manufacturing. Every new production area, from the press shop to the assembly line, was planned, simulated, and stress-tested in a virtual environment long before a single brick was laid. By creating a "Digital Twin" of the factory, BMW was able to identify potential bottlenecks and optimize workflows in the metaverse.

This digitalization extends to the workforce as well. Munich plant employees are currently undergoing intensive training using augmented reality (AR). By practicing complex assembly tasks in a virtual space, they are becoming experts on the new Neue Klasse machinery before the first series-production car even reaches their station. This "upskill to upgrade" philosophy ensures that the human element remains as precise as the technology it manages.

2026 and Beyond: The Future of Munich

As pre-series assembly moves from the nearby Research and Innovation Centre (FIZ) directly into the main Munich plant, the facility has become a fully autonomous hub for the Neue Klasse. Every step of the material flow and process chain is now being refined under real-world conditions.

By the end of 2027, this historic parent plant will make another massive shift, becoming the first location in BMW's global network to produce exclusively all-electric models. The current pre-series production of the i3 isn't just a "test run"—it is the foundation for a future where high-performance driving and digital innovation are built on the same line.

If you are looking for an OEM BMW parts catalog, which includes products such as 2025 BMW i5 parts, check out BMW Discount Parts. All products are factory direct, from BMW, and they include a comprehensive nationwide warranty.

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