Mercedes-Benz has officially started series production of the new-generation GLA at its Rastatt plant in Germany, marking another major step in the company’s transformation of its compact vehicle production network. The new GLA is being manufactured alongside its fully electric counterpart, while advanced hybrid versions using 48-volt technology are scheduled to join production later in 2026.
The latest GLA represents more than a new addition to Mercedes-Benz’s compact SUV lineup. It is also a showcase for the company’s increasingly digital manufacturing strategy, combining flexible production systems, artificial intelligence, digital twins and the Mercedes-Benz Operating System, or MB.OS.
New Mercedes-Benz GLA production begins in Rastatt
The Mercedes-Benz Rastatt plant has been producing compact models since 1992 and has become one of the company’s most important manufacturing locations for vehicles in this segment.
Around 7,000 people work at the site, making it the largest employer in the surrounding region. The plant is designed around a flexible production philosophy, allowing vehicles with different propulsion technologies to be built on the same production line.
That capability is particularly important as Mercedes-Benz continues to transition between combustion engines, hybrids and fully electric vehicles.
The new GLA is currently being produced in Assembly Hall 4.0. Mercedes-Benz plans to move production of the model into the neighbouring Assembly Hall 4.1 from 2027, with the company investing a low-three-digit-million-euro sum in the conversion.
Michael Schiebe, Mercedes-Benz board member responsible for Production, Quality and Supply Chain Management, said the launch reinforces Rastatt’s importance within the company’s global production network.
He also highlighted the increasing role of digital technologies, with MB.OS, artificial intelligence and the company’s MO360 production ecosystem integrated into the manufacturing process.
Mercedes-Benz GLA production uses digital twins
One of the most interesting aspects of the Rastatt transformation is Mercedes-Benz’s use of digital twins.
Before physical construction work begins, engineers can recreate production facilities and manufacturing processes in a highly detailed virtual environment. This allows the company to simulate production lines, identify potential problems and optimise processes before equipment is installed.
Mercedes-Benz says the technology has already helped accelerate the conversion of Assembly Hall 4.0, which was completed in record time in 2023.
The same approach is now being used for Assembly Hall 4.1, with the goal of reducing both construction time and costs.
For Mercedes-Benz, digital manufacturing is becoming increasingly important as vehicle architectures become more complex and production must accommodate several powertrain technologies simultaneously.
New GLA combines electric and hybrid production
The new Mercedes-Benz GLA is being introduced with multiple propulsion technologies, reinforcing the company’s strategy of maintaining flexibility during the transition toward electrification.
The fully electric GLA is already in production at Rastatt, while hybrid versions equipped with 48-volt technology and a new-generation internal-combustion engine will follow later this year.
Building different versions of the same model on a common production line gives Mercedes-Benz greater flexibility when responding to changes in customer demand.
Instead of dedicating an entire factory exclusively to electric vehicles or combustion-powered models, Rastatt can adjust its production mix according to market requirements.
That flexibility is becoming increasingly valuable as the global automotive industry moves through a period in which electric vehicles, hybrids and combustion engines continue to coexist.
MB.OS brings software deeper into GLA production
Software is another major component of the new GLA.
Mercedes-Benz is integrating its MB.OS operating system into the vehicle from the production stage. The company describes MB.OS as a chip-to-cloud architecture designed to simplify the vehicle’s electronic and software infrastructure.
Rather than relying on numerous individual hardware modules for software distribution, the system uses a central server in the Mercedes-Benz Intelligent Cloud.
This approach means vehicles can leave the production line with the latest available software and provides the technological foundation for future software updates and digital services.
The new GLA also introduces advanced interaction technology, including the MBUX Virtual Assistant with generative artificial intelligence.
The objective is to make interaction with the vehicle more natural, allowing occupants to communicate with the car using conversational language rather than relying exclusively on conventional menu structures and commands.
Mercedes-Benz GLA electric components come from Germany
Although final assembly takes place in Rastatt, the new GLA is the product of a broader Mercedes-Benz manufacturing network across Germany.
Electric drive units and axles are supplied by the company’s Untertürkheim operations, including production sites in Mettingen and Hedelfingen.
An electric drive unit incorporates three fundamental elements: an electric motor, power electronics and the transmission system responsible for transferring power to the wheels.
Mettingen is also responsible for assembling complete electric axles, which are then delivered to Rastatt for vehicle production.
The high-voltage batteries are supplied by Mercedes-Benz subsidiary Accumotive from Kamenz in Saxony.
Accumotive has more than a decade of experience in battery manufacturing and is described by Mercedes-Benz as one of the company’s centres of excellence for high-voltage battery systems.
The company operates within Mercedes-Benz’s wider global battery production network, which spans three continents.
Kuppenheim supplies body components for the new GLA
Another important link in the GLA production chain is located just 10 kilometres from Rastatt.
The Mercedes-Benz Kuppenheim site has supplied body-in-white components, structural components and body parts to Rastatt since 2009. It is now also supporting production of the new GLA.
Since the beginning of 2026, Rastatt and Kuppenheim have been more closely integrated from an organisational perspective, with Kuppenheim becoming part of the Mercedes-Benz Rastatt plant.
The closer connection between the two sites is designed to strengthen production efficiency and coordination.
New Mercedes-Benz GLA gets a sportier design
Beyond its manufacturing technology, the new Mercedes-Benz GLA brings a substantially revised exterior and interior design.
The latest model adopts a lower silhouette and longer wheelbase, giving the compact SUV a sportier stance. One of its most distinctive elements is the illuminated Mercedes-Benz grille, which gives the front end a more recognisable appearance, particularly at night.
Mercedes-Benz has also redesigned the interior around increased digitalisation and improved practicality.
A large MBUX Superscreen dominates the dashboard, while higher-quality materials and a redesigned cabin aim to increase the perceived sophistication of the compact SUV.
The available panoramic roof adds to the feeling of space, while the longer wheelbase is intended to improve interior room and everyday versatility.
MBUX Virtual Assistant adds generative AI
The new GLA is also part of Mercedes-Benz’s broader move toward artificial intelligence inside the vehicle.
The MBUX Virtual Assistant incorporates generative AI technology to provide more natural interaction between driver and vehicle.
Instead of requiring drivers to navigate through conventional menus, the system is designed to understand more conversational requests and provide personalised assistance.
This represents another step in the evolution of Mercedes-Benz’s MBUX infotainment system, with software increasingly becoming as important to the vehicle experience as traditional mechanical hardware.
Rastatt becomes a key Mercedes-Benz compact-car hub
The launch of the new GLA further strengthens Rastatt’s position within Mercedes-Benz’s global production network.
The plant is now producing vehicles based on the company’s latest generation of technology while simultaneously supporting multiple propulsion concepts.
That combination of flexible manufacturing, digital production technologies and vertically integrated component supply is becoming increasingly important for Mercedes-Benz as the company adapts to changing global demand.
The ability to produce electric, hybrid and conventional vehicles within the same manufacturing environment gives Rastatt a significant degree of operational flexibility.
For the employees at the site, the GLA launch also represents a major investment in the plant’s future.
Torsten Höink, Chair of the Works Council at Mercedes-Benz Rastatt, described the start of production as an important new chapter for the facility and emphasised the role of innovation, expertise and teamwork in its long-term development.
The new GLA marks a new era for Mercedes-Benz
The start of production of the new Mercedes-Benz GLA is significant for reasons that extend well beyond the compact SUV itself.
It demonstrates how Mercedes-Benz is reshaping its manufacturing operations around a mixed powertrain strategy while simultaneously increasing the importance of software, artificial intelligence and digitally managed production.
With electric, hybrid and conventional technologies being accommodated within a flexible manufacturing environment, the Rastatt plant is effectively being prepared for an automotive market that remains in transition.
At the same time, the new GLA itself moves further into the digital era with MB.OS, the MBUX Superscreen and a generative-AI-powered virtual assistant, while its redesigned exterior and interior give Mercedes-Benz’s compact SUV a more distinctive and sophisticated character.
As production expands into Assembly Hall 4.1 from 2027, the GLA will become an even more important part of Rastatt’s next chapter — and another example of how Mercedes-Benz is combining traditional German manufacturing expertise with software-driven vehicle technology.
Source: Mercedes-Benz
