From Normal to 400K EVs a Year, Rivian Is Just Getting Started

If you’ve ever told someone you drive a Rivian and got hit with “What’s a Rivian?” or “Is that made in China or something?”, you’re not alone. Turns out, Rivian is very American.

Rivian is steadily scaling up its U.S. manufacturing footprint, and that’s not just good news for EV fans; it’s a big win for local jobs, smart production, and the future of clean mobility. In a recent Rivian Stories interview, COO Javier Varela gave a behind-the-scenes look at how Rivian’s expanding operations are taking shape in Normal, Illinois, and what’s next for the company’s upcoming Georgia plant.

Rivian currently builds every R1T, R1S, and commercial van at its Normal plant, a facility that now spans 4.3 million square feet. And that’s still growing. The company is in the middle of adding another 1.1 million square feet to prepare for the production of the new R2.

But the story here is more than just real estate. Varela emphasized that the real magic is the people. When Rivian took over the Normal plant, it was just weeks away from demolition. Now, it’s home to thousands of employees and some of the most advanced EV manufacturing tech in the country.

That tech includes a strong dose of robotics and AI, but Varela made it clear that humans are still the core of Rivian’s process. From thoughtful part placement to smarter line layouts, team members on the ground drive continuous improvements; technology simply helps multiply that impact.

The R2 expansion isn’t just about adding space either. It’s guided by lean manufacturing principles from the start, using the Rivian Production System to keep things flowing efficiently with minimal waste. That includes just-in-time delivery, careful planning to avoid disruption during plant downtime later this year, and even integrating parts of the R2 process with the R1 line to boost efficiency.

Looking further ahead, Rivian’s new factory in Stanton Springs, Georgia, will take everything they’ve learned in Normal and scale it up even more. Built from the ground up, the Georgia plant will be tailored for Rivian’s preferred manufacturing style and aims to produce over 400,000 vehicles per year once it’s fully operational. Like Normal, it’ll support thousands of jobs and feature high levels of vertical integration.

It’s a big move, but one that feels deliberate. Rivian isn’t rushing; they’re building with intention, and the foundation looks solid.