BMW has detailed the sustainability strategy behind the new i3, the second model built on its Neue Klasse architecture. The vehicle targets decarbonization across the full lifecycle, from supply chain through production and customer use. Overall, the i3 incorporates approximately 30% secondary materials by total vehicle content.
Highlights
- Supply chain CO2e emissions reduced by approximately one-third compared to industry averages during product development
- Gen6 battery cells cut CO2e by 33% per watt-hour versus the previous Gen5 cells
- Front bumper recyclable plastic content rose from 46% to 85%, while material types dropped from 15 to 7
- Plant Munich will transition to an all-electric Neue Klasse portfolio by 2027
Supply Chain Decarbonization
BMW focused on three levers to reduce supply chain emissions. These include renewable energy sourcing, higher secondary material content, and process innovation. The Gen6 battery cell and high-voltage battery were specific targets for optimization.
As a result, specific product development measures lowered the i3’s supply chain CO2e by roughly one-third. That figure is based on comparison with industry averages from a recognized lifecycle assessment database.
Secondary Materials Breakdown
The i3 uses secondary materials across multiple major components. Cast aluminum knuckles contain 80% secondary content, while cast aluminum wheels use 70%. The rear electric motor housing, produced at BMW Plant Landshut, comprises up to two-thirds secondary aluminum.
Additionally, the engine compartment cover and under-bonnet storage use 30% recycled maritime plastic. This material comes from post-consumer fishing nets and ropes. Headliner, A-pillar, and parcel shelf textiles use yarn made entirely from recycled material.
Gen6 Battery Cell Improvements
The Gen6 cells in the i3’s high-voltage battery incorporate secondary cobalt, lithium, and nickel. Renewable energy powers the manufacturing of anode and cathode materials, as well as cell production itself. Compared to the Gen5 cell used in the BMW i4, CO2e emissions fell by approximately 33% per watt-hour.
Design for Circularity
BMW expanded its “Design for Circularity” principles in the i3. The front bumper trim uses 30% recycled plastic. At the same time, material variety across the entire bumper dropped from 15 types to 7 versus the predecessor 3 Series. Consequently, recyclable plastic content increased from about 46% to approximately 85%.
The Econeer seat covers, part of the Essential equipment line, use a recyclable textile composite. The upper fabric base material is 100% recycled PET. BMW also improved the seat cover’s dismantling capability for end-of-life material separation.
EfficientDynamics and Use Phase
BMW’s EfficientDynamics package optimizes efficiency across all vehicle subsystems during customer use. This covers aerodynamics, lightweight construction, rolling resistance, and energy management. The company has applied EfficientDynamics across all drivetrains since 2007.
Depending on drivetrain variant, mileage, and charging source, the i3 50xDrive achieves a CO2e advantage over a comparable ICE model after one to two years.
Plant Munich Production
BMW Group Plant Munich will begin production of the new i3 in 2026. The facility has undergone a four-year modernization, including a new body shop and vehicle assembly hall. The plant sources 100% of its external electricity from renewable energy.
By 2027, the Munich location will produce exclusively fully electric Neue Klasse vehicles. BMW has also committed to publishing TÜV-validated Vehicle Footprint reports for all i3 drivetrain variants.
BMW Group Emissions Targets
The BMW Group has committed to reaching net-zero emissions no later than 2050. The company aims to cut CO2e by at least 40 million tonnes from 2019 levels by 2030.
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