Frames, swing arms and gas tanks have been welded at the Berlin plant since 1968. Today, state-of-the-art robot systems are in use that support a team of highly trained staff.
The tank of an R1250 GS Adventure or the BMW S 1000 RR is made from several individual parts by a welding robot. It is then further processed manually. A worker can work on up to 50 gas tanks a day and takes care of the areas that a robot cannot handle. The biggest challenge is to weld the aluminum, which is only 1.5 millimeters thin, as even the smallest mistake would cause the tank to leak. That’s the Champions League of welding.

Following the leak test, the tank is further processed in the paint shop.