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Rivian, the electric vehicle manufacturer, is significantly expanding its manufacturing operations in Normal, Illinois, to support the production of its upcoming R2 vehicle. The expansion includes the construction of a new 1.1 million square-foot facility dedicated to body shop and general assembly operations, along with additional structures for paint, battery, and material flow. This project is part of Rivian’s strategy to begin R2 deliveries in 2026 and will increase the plant’s total production capacity to 215,000 units. Leveraging its existing 4.3 million square-foot facility, where it currently produces the R1 and commercial vans, Rivian aims to expedite the launch of the R2 by utilizing its experienced workforce and established infrastructure in Normal.
Building big for R2! Take a closer look at our 1.1 million sq ft expansion at our Illinois plant that's on track to bring R2 to market in 2026.
— Rivian (@Rivian) March 25, 2025
Get the inside story: https://t.co/sWk9nClyRV pic.twitter.com/CuGnp1mTTq
Key Highlights
- A new 1.1 million square-foot building for R2 body shop, general assembly, and end-of-line operations.
- Construction is advancing rapidly, with roof work nearly complete and interior work already underway in some areas.
- Prefabrication is being extensively used to accelerate the building process and minimize on-site assembly.
- The expansion optimizes the plant’s layout by utilizing available space on the south and east sides, requiring the decommissioning of the old test track and the construction of a new high-speed test track.
- Efficiency improvements include removing parts painting from the main paint shop and implementing conveyance systems and automated storage for smoother production flow.
Despite the challenges of winter weather in Illinois, construction remains on schedule. The new buildings are progressing well, with the Body, General Assembly, and End of Line facility already having its walls completed, 70% of structural steel in place, and 60% of roof decking finished. Additionally, the Parts Pre-Treat and E-Coat Dip (PTED) building is almost weather-tight, and equipment installation is set to begin soon. Rivian’s VP of Production Facilities, Tony Sanger, emphasized the importance of prefabrication in speeding up the project, noting that it reduces the need for on-site connections and enables faster assembly.
Rivian is committed to meeting its 2026 production timeline for the R2. Sanger expressed confidence in the progress, stating, “We are on track to bring R2 to market in 2026, as planned, and we couldn’t be more excited.” The expansion is designed to enhance production efficiency, with key improvements such as dedicating the main paint shop exclusively to vehicle bodies and implementing advanced systems for material handling. These changes will help Rivian achieve the high-volume production required for the R2.
The project’s complexity and pace demand strong collaboration across Rivian’s teams. Sanger highlighted the excitement of working on such a dynamic initiative, saying, “Speed and complexity require a high level of collaboration. These are the truly fun programs to work on in my line of work.” The successful completion of this expansion is critical to Rivian’s ability to deliver the R2 to customers on time, marking a significant milestone in the company’s growth.
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