Rivian is ahead of schedule on its expansion in Normal, Illinois, as it prepares for the launch of its next-generation electric SUV, the R2, in 2026.
The expansion is a new 1.1 million square-foot building on the east side of Rivian’s manufacturing campus in Normal, Illinois. This structure will house the body shop, general assembly, and end-of-line operations for the R2. Additional facilities are also being built for paint, battery systems, and improved material flow. Once completed, the expansion will increase the plant’s total annual production capacity to 215,000 vehicles.
Prefabrication has been a key factor in speeding up construction, according to Tony Sanger, Rivian’s VP of Production Facilities. “We’ve made every effort to prefabricate as much as possible to reduce the number of field connections. This allows us to move faster and keep our timeline on track,” he said in a post on Rivian’s website.
Sanger confirmed that the new Body, General Assembly, and End-of-Line building is already complete for walls, 70% finished for structural steel, and 60% complete for roof decking. The Parts Pre-Treat and E-Coat Dip (PTED) building is nearly weather-tight, with equipment installation beginning soon.
Efficiency improvements are also being built into the expanded facility. All parts painting will now occur in the new PTED building, freeing up the main paint shop to focus exclusively on vehicle bodies. Conveyance systems and Automated Storage and Retrieval Systems (ASRS) will streamline material movement between body, paint, and assembly, helping Rivian meet high-volume production goals.
The expansion also required Rivian to decommission its original test track. A new high-speed track is already under construction and is expected to open this spring.
Rivian’s Normal facility currently produces the R1T, R1S, and commercial delivery vans, which are no longer exclusive to Amazon and available for anyone to purchase. The new R2 will be a more affordable, five-seat SUV with an expected price of around C$65,000. It boasts a projected range of over 480km (300 mi) and will accelerate to 60mph in around three seconds.
