Unlocking Audi’s Electric Future in Győr: An Inside Look at the Production of PPE

After driving the Audi A6 e-tron and S6 e-tron for a few days, it was like coming back home when we arrived at Hungary after driving all the way from Munich. After all, the two cars are produced right here in Gyor, Hungary, the home of PPE production.

We got an inside look at how the factory produces one of the most important platforms for Audi, which underpins the brand’s latest electric vehicles. Here’s what we learnt.

Standing at the e-motor Line: Engineering in Motion

The first stop: the e-motor line, an arena of precision and innovation. Here, I watched the transformation of raw materials into ultra-compact, efficient electric motors that power models like the Audi A6 e-tron. Audi Hungary has outfitted a 15,000 m² production area with three brand-new lines dedicated to these drive systems: 28 work steps for stator production, 15 for transmission components, and a staggering 190 steps to assemble each axle.

What struck me immediately was the scale and cohesion of the operation. Around 700 employees, working across three shifts, are able to build up to 2,000 electric motors per day. It’s a symphony of human skill and technological precision, hands guiding components into place and robots assisting with high-pressure steps. The vertical integration is impressive: here, stators, transmission parts, and axles are all produced and assembled in-house, a step forward even from earlier e-drive systems.

With an Expert at the PPE Line: Deep Dive into Drive System Innovation

At the PPE production line, we got to see the stator line, which alone uses 15 automatic bending machines to craft three-dimensional “hairpin” windings, each stator consuming roughly 140 meters of copper wire, and requiring 235 laser-welding seams to seal the ends.

The hairpin winding allows a fill factor of 60 percent, up from only 45 percent in older designs. Combined with silicon carbide semiconductors in the inverter and an electric oil pump in the transmission, Audi has achieved a monumental 50 percent reduction in drag losses. The result? Motors that are 20 percent lighter and 30 percent more compact, delivering 60 percent higher power density than first-generation systems.

Audi also emphasised its strides in acoustics: motor mounts molded directly onto the housing, improved tooth geometry, and segmented rotors all contribute to an exceptionally quiet, comfortable drive.

A highlight of the discussion was vertical integration. Unlike earlier models—for example, the first-generation e-tron motors—Audi now produces transmissions for the PPE platform entirely in-house. For future projects, the aim is to continue expanding this capability.

Hands-On: Build-Your-Own e-motor Workshop

Perhaps the most memorable moment came in the workshop, where I got hands-on with PPE components. Under the guidance of an engineer, I helped assemble a basic version of an electric motor. Although there are less parts than in an ICE drivetrain, it still required a lot of precision!

This interactive experience revealed Audi’s commitment to skilled training. Employees around the line undergo classes such as High-Voltage Sensitisation; tasks near the line require just two hours of basic training, but for “electrical specialists,” several days are needed, and the top tier - “electrical specialist in charge” - can take up to three months of in-depth training. Since 2022, some 2,000 employees have been redeployed and retrained, drawing from Audi Hungary’s combustion-engine heritage to pivot into electrification.

The Big Picture: Győr’s Electrification Milestone

My tour wasn’t just about seeing clever engineering; it was about witnessing Audi Hungary’s pivotal transformation in the global electrification strategy.

First, the site is carbon-neutral since 2020, powered by Europe’s largest rooftop solar farm and the country’s largest industrial geothermal operation.

Second, through forward-thinking logistics - like using carbon-neutral rail transport via DB Cargo - Győr ensures that even deliveries of PPE motors to Ingolstadt are sustainable.

Third, the use of VR glasses to design the new production lines marks a new era of digitalised factory planning - an Audi Hungary first - as production engineering and tooling experts from Győr and Ingolstadt collaborate on layout and optimisation.

Finally, beyond Audi, Győr is becoming a powertrain hub for the entire Volkswagen Group. The plant already serves Audi, Porsche, and will soon support MEBeco-based vehicles too - a reflection of its strategic value in the electrified future.

Conclusion: A Journey into Audi’s Electric Heart

My visit to Audi Hungary’s Győr facility was a journey into the beating heart of Audi’s electric transformation. From the meticulously engineered stators and transmissions to the expert-led workshop, it was clear that Audi is serious to up its game in electrification. I think it has a fighting chance with the PPE, if my experience is of any indication.

Photos by James Wong

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