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Munro & Associates recently conducted a hoist review of the new BMW i7, providing valuable insights for automotive engineers, EV enthusiasts, and industry investors. Through expert teardown analysis and lean manufacturing principles, this hoist review highlights key aspects of the BMW i7’s chassis. In addition, it examines the suspension system and explores the multi-material body design.
As BMW transitions to electrification, it also works to maintain its legacy as an “ultimate driving machine.” This review provides a clear look at the strengths and trade-offs in the vehicle’s underlying architecture.
BMW i7 Platform and Structural Design
The reviewed BMW i7 rides on BMW’s CLAR (Cluster Architecture) platform, which supports both internal combustion engine (ICE) and battery electric vehicle (BEV) configurations. This dual-purpose approach affects several engineering choices. From the hoist view, much of the visible structure consists of aluminum and steel, rather than the extensive carbon fiber previously seen in older 7 Series variants. The platform’s flexibility means BMW must balance structural needs for both ICE and BEV configurations—impacting both cost and weight optimization opportunities.
One of the standout features is the front end structural module (FESUM), predominantly built from aluminum. The team observed a variety of manufacturing techniques here: MIG welding, one-sided welds, extrusions, and bolted crush cans for the front impact beam assembly. This diverse fastening strategy highlights BMW’s pragmatic approach—selecting manufacturing methods based on the demands of each structural element.
A key detail is the large forged aluminum “tusk” extending from the front cradle. This element is forged, not cast. The reason: superior crash absorption and elongation properties. It helps manage frontal impact energy and strengthens the vehicle’s structure.
Balancing Mass and Performance
At over 4,900 pounds, the BMW i7 is a heavy luxury sedan. Mass begets mass, even with extensive use of aluminum. The team noted thick extrusions in the front-end structure—measuring around five to seven millimeters—demonstrating the need for significant strength to manage such weight. This trade-off between mass and crashworthiness is a recurring theme in the i7’s design.
Suspension Insights: Engineering for Driving Dynamics
The front suspension employs a virtual ball, short-long arm (SLA) setup—an approach synonymous with BMW driving dynamics. Forged aluminum components are prevalent, reducing unsprung mass and improving handling. The air suspension system appears to offer per-corner control, allowing real-time corner balancing and load leveling—essential for a vehicle of this size and weight.
BMW’s integration of these systems aligns with its brand ethos: delivering both comfort and dynamic control. Notably, the team observed a typical BMW dual-material brake disc, with an aluminum hat mated to a steel rotor—another example of weight-conscious design aimed at optimizing driving dynamics.
Battery Pack and Platform Trade-offs
A significant focus of the review was the battery pack structure and its integration with the CLAR platform. The i7 employs extruded aluminum cross-members with friction stir welds—offering superior structural performance and preserving aluminum temper better than MIG welds. The team highlighted the precision and cleanliness of these welds, common in industrial applications but still relatively rare in automotive.
Interestingly, the battery pack features a composite SMC lid and a heat shield. This is an unusual choice. It was likely driven by the need to accommodate both ICE and BEV versions on the same platform. These heat management elements reduce thermal transfer between the battery and cabin. That trade-off stems from the CLAR platform’s multi-use design.
Overall, while a BEV-specific platform might allow for lighter, more cost-effective integration, BMW’s choice to leverage the CLAR architecture offers manufacturing flexibility and economies of scale. This mirrors a common industry challenge: balancing BEV optimization with the cost advantages of shared platforms.
Rear Structure and Handling Enhancements
At the rear, the i7 features a complex cradle assembly with distinct cast and extruded aluminum elements. The hoist review revealed a rear steering system—similar to those used in high-end German sedans like the Audi Q7—providing low-speed maneuverability and high-speed stability. The rear steering mechanism appears compact, offering subtle but effective angle adjustments.
BMW’s attention to structural rigidity is further evidenced by the extensive underbody bracing—typically seen in convertible models. This galvanized steel weldment ties the rear cradle to the body, enhancing torsional stiffness and maintaining handling precision despite the platform’s inherent compromises.
Lean Design and Cost Considerations
A consistent theme throughout the review is the application of lean design thinking. Munro’s team discussed how integrated casting strategies—such as those used by Tesla’s Giga presses—could further simplify the i7’s structure and reduce part count. However, they also noted that achieving such integration involves trade-offs in tooling cost, supplier availability, and development timelines.
BMW’s approach reflects a careful balance: leveraging proven manufacturing techniques while preserving flexibility across model variants. The review emphasized how Munro assists clients with activity-based costing, helping OEMs evaluate the ROI of integrated solutions versus more modular designs.
Opportunities for Future Optimization
Several elements of the i7 suggest opportunities for further lean manufacturing gains:
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Air suspension components: The current standalone tank and pump could be integrated into structural cross-members—similar to Tesla’s approach—reducing cost and packaging complexity.
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Brake discs: While dual-material discs reduce unsprung mass, they introduce manufacturing complexity; OEMs must continually assess whether the performance gains justify the added cost.
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Rear impact beam: The team noted an innovative stamped steel weldment with a secondary hat section—an elegant solution for adding section stiffness without excess weight.
These observations illustrate the incremental gains possible even in mature vehicle programs—key to maintaining competitiveness as the industry pushes for lower costs and higher margins in EVs.
Conclusion: BMW i7 as a Study in Trade-offs
The BMW i7 hoist review underscores the inherent trade-offs of adapting a dual-use platform for premium EV applications. While not as lean as a ground-up BEV architecture, the i7 exhibits high levels of structural sophistication, exemplary build quality, and hallmark BMW driving dynamics.
For automotive engineers, this teardown analysis offers valuable lessons. It shows how expert engineering can reconcile legacy platform constraints with modern EV performance demands. For EV enthusiasts and investors, it offers valuable insights. It highlights the pragmatic paths OEMs must follow to remain cost-competitive. At the same time, they must continue delivering luxury and performance.
Discover More Expert Insights with Munro
As always, lean design, expert teardown insights, and continuous optimization remain essential tools in navigating the evolving automotive landscape. To explore more in-depth analyses and reports, visit Munro & Associates and subscribe to Munro Live—where cost, efficiency, and innovation drive the future of mobility.