BMW’s Spartanburg, South Carolina, plant has evolved significantly since the automaker announced plans for its first U.S. factory in 1992. Today, the facility focuses on BMW’s “X” SUV lineup, including the new X5, while also serving global markets and ranking as the largest U.S. automotive exporter by value.
Inside BMW’s Spartanburg X5 Production
Production at Spartanburg began in 1994 with models such as the E36 3 Series. The plant has since shifted its focus to BMW’s X models, reflecting strong U.S. demand for SUVs.
The Neue Klasse era has reached Spartanburg with the new X5 (G65), which incorporates BMW’s latest design language and technology. A FRAME walkaround on YouTube provides a look at how the X5 is built, from metal stamping through final assembly. The model serves as BMW’s answer to the Audi Q7 and Mercedes-Benz GLE.
How BMW Builds the X5
The process begins in the stamping shop, where automated Schuler servo presses use massive dies to form flat metal blanks into body panels, including hoods and side frames. Robots move the panels between stations, while scanners and factory specialists inspect them for defects and dimensional accuracy.
The panels then move into the highly automated body shop, where more than 2,000 robots clamp, weld and assemble the vehicle’s structure. BMW has deployed humanoid robots at several plants to assist workers, although none were visible during the walkaround.
Resistance spot welding is used to join the metal without the dramatic sparks typically associated with welding. Other stations use arc welding, where sparks are more visible. Once the body-in-white is complete, automated optical systems measure it before it moves to the painting area.
Painting and Final Assembly
Rust protection begins with an electrocoat dipping process. The body is rotated during the process to help ensure the coating reaches every cavity.
Robots then apply sealant, primer and paint. The finished body undergoes visual and tactile inspections inside a brightly lit inspection tunnel before moving to final assembly.
At the so-called marriage station, the painted body is joined with its powertrain. The U.S.-spec X5 will initially be available as the X5 40 xDrive, powered by a 3.0-liter turbocharged inline-six gasoline engine with 48-volt mild-hybrid assistance. It produces 394 horsepower.
Plug-in-hybrid and all-electric versions are scheduled to follow by 2027. During final assembly, technicians install the interior, doors, glass, wheels, fluids and badges. The process concludes with final inspections, including an evaluation by a BMW test driver.
BMW X5 Lineup and Pricing
The base X5 40 starts at $69,800, while the all-wheel-drive X5 40 xDrive starts at $72,100. The X5 50e xDrive plug-in hybrid starts at $77,500.
Above it sits the all-electric iX5 60 xDrive, which starts at $79,800. The EV produces 570 horsepower and offers an estimated range of up to 435 miles, based on preliminary BMW testing using EPA procedures.
Other BMW Models Built in Spartanburg
The Spartanburg plant also produces the X3, X6, X7 and XM. The X4 was previously built at the facility, but production ended in 2025.
A fully electric successor to the X4 is reportedly scheduled to enter production at BMW’s Debrecen plant in Hungary in late 2026.
