Rivian Expands U.S. Manufacturing Ahead of R2 SUV Production

Rivian is scaling up its American manufacturing operations as it prepares for the production of its upcoming R2 electric SUV. The EV maker’s flagship facility in Normal, Illinois, is currently undergoing a major expansion to accommodate new models and improve efficiency, while a second plant in Georgia is in the works to support long-term growth and global distribution.

The company says the expansion reflects both its commitment to U.S. manufacturing and the importance of local job creation as it accelerates EV adoption.

Normal plant expansion paves the way for R2 SUV

Rivian’s Illinois facility, which already builds the R1T pickup, R1S SUV, and commercial vans, is set to add the more affordable R2 SUV in 2026. The plant currently spans 4.3 million square feet and employs thousands, but an additional 1.1 million square feet is being added to support the upcoming R2 production line.

Chief Operating Officer Javier Varela highlighted the use of advanced robotics, AI, and lean manufacturing principles through the Rivian Production System (RPS) in a blog post. The goal, he said, is to build an efficient, flexible assembly process from day one. Rivian is also integrating some R2 operations into the existing R1 line to streamline production and minimize downtime during the transition.

Georgia facility will anchor long-term global strategy

Rivian’s new plant in Stanton Springs, Georgia, is expected to eventually produce more than 400,000 vehicles annually with a high level of vertical integration. Unlike the retrofit approach taken in Illinois, the Georgia facility is being designed from the ground up with Rivian’s manufacturing philosophy at its core.

“Based on our Rivian Production System, we’ve developed a very strong manufacturing culture in Normal, Illinois, and are excited to bring that to a new facility that we will build from the ground up. So, while these two plants will share many things, our Stanton Springs, Georgia plant will be designed around the way we want to build vehicles, rather than us building processes around an existing manufacturing footprint,” Varela said.

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