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Inside Rivian’s California battery lab: 180 kWh ‘megapacks’, carbon fiber, and ballistic shields

Published

7 years ago

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I found myself perplexed when I heard about Rivian’s plan to unveil an all-electric pickup truck with a battery pack nearly double the size of any other electric vehicle. Packing 80% more energy than Tesla’s flagship Model S and Model X, Rivian’s 180 kWh battery pack enables their full-size, adventure vehicles to travel 400+ miles (643 km) on a single charge. Rivian’s response? We actually call it the “megapack.”

At a flashy unveiling event in Los Angeles, the Michigan-based electric car company exited stealth mode and debuted their first two production vehicles: an all-electric pickup truck dubbed the R1T and an R1S luxury SUV. Capable of towing 11,000 lbs from its all-electric powertrain, the R1T is set to disrupt a $95-billion-dollar US truck market that’s largely dominated by Ford and GM. Rivian’s seven-seater, R1S SUV takes aim directly at gas guzzlers that are competing in the premium sports utility segment like Land Rover and Porsche’s Cayenne. 

Powering the R1T Truck and R1S SUV is a quad-motor electric drivetrain that’s paired with one of Rivian’s three battery pack configurations, in 105 kWh, 135 kWh, and 180 kWh (the “megapack”). Rivian’s 180 kWh megapack holds enough energy to power a typical US household for more than two weeks. To learn more about the engineering that goes into each of Rivian’s battery packs, and the company’s plan to bring their ultra-long-range battery packs to market, I visited their research and development facility in Southern California.

The Rivian R1T and R1S take center stage at the 2018 LA Autoshow

The Battery Lab

Rivian’s battery lab is located in an unassuming industrial business park in Irvine, California. Still working its way out of nine-years in stealth mode, the 19,000 sq ft facility lacks any signage on its doors, yet has played a major role since mid-2017 when the company moved in to begin its research and development.

Upon entering the battery lab, I was greeted by the faint hum of testing equipment around me. Bright white lights illuminate a team of engineers in blue Rivian lab coats. I was told that the lab is where Rivian performs tests on the lithium-ion battery cells being used in its vehicles. The lab is also where battery module production is currently taking place, albeit mostly for prototype battery packs. 

Leading Rivian’s battery and powertrain development is former hypercar engineer Richard Farquhar, who enjoys an insanely fun-sounding title: VP of Propulsion. Farquhar is one of the many members to recently join Rivian from renowned supercar brand McLaren. Rivian has brought on seven executives from the British company since late 2017, including Executive Director of Engineering and Programs, Mark Vinnels.

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(Photo: Rivian)

Rivian’s Battery Cells and Supplier

As Farquhar and I walk past a long row of glass cabinets, seen packed with hundreds of cylindrical battery cells in their testing phase, his eyes lit up with excitement while discussing the most intricate elements of the lithium-ion cells. “We want to understand the battery cells even better than their manufacturer,” Farquhar tells me.

It was the perfect segue I was looking for. “So, where is Rivian getting these battery cells from?” I ask. Farquhar wasn’t able to share the name of their battery partner but emphasized that Rivian wasn’t worried about their supply of cells. “I have no concern whatsoever,” Farquhar emphatically stated.

While Rivian isn’t ready to announce a battery supplier (yet), U.S. customs import records suggest that the company could be partnering with LG Chem to procure their cylindrical 2170 form factor lithium-ion cells. Rivian imported nearly 12,933 kg (28,500 lbs) of the 2170 cells from LG Chem in 2018 thus far — enough to support a test production run of ~195 Rivian battery modules at 15 kWh each.

Designed for extreme conditions

Inside the cabinets were cells being cycled through various charge and discharge states, and at various temperatures. Rivian wants to be the leading experts on battery technology, and in lieu of having numerous vehicles on the road, the company is testing its batteries using real-world simulations.

In the office area next to the lab, engineers analyze the testing data in real-time while adjusting computer-generated models. These tests aren’t just being done for a few hours or days, Farquhar tells me. One battery test has been ongoing for 11 months and counting. Rivian plans to analyze battery cell behavior over time and collect as much data as possible before making adjustments to it and entering production.

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One row of Rivian’s battery cell testing rigs collecting data from the cells as they are charged and discharged on various cycles. (Photo: Rivian)

While standing the test of time is incredibly important for all battery cells, standing up to extreme conditions is just as critical. On one side of the lab, special climate-controlled containers simulate extreme temperature scenarios and test how the cells, modules, and full-sized battery packs react to these conditions. Rivian expects their adventure-ready vehicles to be capable of handling extreme temperatures and climates. Pushing their batteries to the limit isn’t just a precaution, but a necessity.

From Battery Cells to Modules

Farquhar tells me that Rivian engineers have worked on battery algorithms that leverage a driver’s profile, including their location and navigation data, and real-time weather conditions, to preemptively optimize a battery.  For example, when a vehicle is on its way to a DC-charging station, the battery modules will be cooled ahead of time and prepared to accept the fastest charging rate. In essence, Rivian’s battery algorithms are adjusting battery cell settings, constantly, on the fly. By using machine-learning to build predictive models of various conditions, Rivian is able to tune battery cells, with high confidence, on conditions it may encounter. 

Rivian’s R1T pickup truck and R1S adventure SUV will use the exact same battery modules. Battery capacity will vary based on the number of modules inside a skateboard-style battery pack design. Each Rivian module holds 864 cells, with 432 on the bottom and the other half stacked on top. In between the cells is a thin 7mm aluminum plate with liquid coolant. The unique structure isn’t known to be used by any other manufacturer.

 

A battery’s cooling system is one of the most important components within an electric car. If the batteries get too hot from fast charging or extended periods of high output, they could degrade in energy capacity and face permanent damage. If the batteries get too cold, they lose range. Keeping the batteries at their optimum temperature is a constant battle and is what truly differentiates any electric vehicle manufacturer.

Rivian’s solution to battery thermal management is the use of a cold plate that’s placed between two battery cells. A single cooling system chills both layers of cells at the same time. According to Rivian, this reduces the amount of energy needed to power the system, thereby allowing the car to have better range in all types of conditions. In addition to saving power, the cooling system’s design allows for tighter packaging of cells within the modules. According to Farquhar, Rivian’s unique packaging allows the module to be 25% denser than any other battery module on the market. 

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Rivian’s Battery Pack: Carbon Fiber and Ballistic Shields

I saw it from afar. Carbon fiber. Walking toward a station that was outfitted with Rivian’s line of 135 kWh and 180 kWh battery packs, my eyes were immediately drawn to a fibrous-looking cover plate. 

Securing Rivian’s battery modules and high-voltage cabling in place is a carbon-fiber composite shell. Engineers were able to create a unique, high-strength geometric shape out of the carbon fiber while keeping weight to a minimum. Rivian seals the battery pack to be completely watertight. The pack is bolted into the frame of the vehicle and then covered by a smooth ‘ballistic shield’, which prevents damage to the underside of the battery pack and protects occupants within the vehicle’s cabin. The ballistic shield is fitted to the entire underbody of the vehicle.

Engineers place the top carbon-fiber shell on the battery pack. A sealant between the top and bottom shells creates a watertight seal. (Photo: Rivian)

Having a watertight battery pack that’s armored by a ballistic shield bodes well for a company whose mission is to build extreme off-road vehicles. That’s the messaging Rivian wants consumers to see. The vehicles are designed to be adventure-ready,  being able to wade through 1 meter of water, climb 45-degree inclines, and drive over boulders.

Rivian’s Executive Director of Engineering and Programs, Mark Vinnels, told Teslarati that they dropped the vehicle on a boulder from 2 ft in the air, just to be able to verify the battery pack’s integrity in extreme off-road situations.

What about Production?

With the design of its battery module completed, a significant portion of the team’s focus has turned to module production — specifically, designing methods to quickly and efficiently manufacture modules by using automation. Rivian has set up a pilot production line at the Irvine facility, ahead of its anticipated summer 2020 production.

(Photo: Rivian)

Rivian is actively developing automation processes for the entire battery module assembly. In a corner of the battery facility were two Japan-made robots that were brought in from the company’s massive factory in Normal, Illinois. A robotics technician was actively working on the robots, while I watched a module come together on the line.

The entirety of Rivian’s module and battery pack production is slated to be installed in a 300,000 sq-ft section of Rivian’s 2.6M sq ft factory in Normal, IL. The plant was acquired by Rivian in 2017 for $16M and originally part of an expansion made by Mitsubishi that the Japanese automaker never occupied. Farquhar stated that the area is virtually a “clean slate.”

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ALSO SEE: Rivian R1T and R1S: Top 10 hidden features that make an electric off-road vehicle

Rivian expects to start deliveries of the R1S and R1T in the second half of 2020, with the largest battery packs entering production first. The R1S SUV starts at $72,500 (before tax credits) and has a range that varies between 240 to 410+ miles (385 to 660 km). Rivian’s R1T pickup truck has a starting price of $69,000 and similar range as the R1S at 230 to 400+ miles (370 to 643 km), depending on battery pack size. Both vehicles will support CCS DC-fast charging up to 160 kW and are capable of accelerating from 0-60 mph in 3 seconds.

Rivian is accepting preorders at its website.

Inside one of Rivian’s paint lines at their factory in Normal, IL. Rivian acquired the former-Mitsubishi plant in January 2017 for $16M. (Photo: Christian Prenzler/Teslarati)
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Christian Prenzler is currently the VP of Business Development at Teslarati, leading strategic partnerships, content development, email newsletters, and subscription programs. Additionally, Christian thoroughly enjoys investigating pivotal moments in the emerging mobility sector and sharing these stories with Teslarati's readers. He has been closely following and writing on Tesla and disruptive technology for over seven years. You can contact Christian here: christian@teslarati.com

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Elon Musk

‘I don’t understand TSLAQ:’ notable investor backs Tesla, Elon Musk

Published

3 hours ago

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October 8, 2025

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tesla showroom
(Credit: Tesla)

One notable investor that many people will recognize said today on X that he does not understand Tesla shorts, otherwise known as $TSLAQ, and he’s giving some interesting reasons.

Martin Shkreli was long known as “Pharmabro.” For years, he was known as the guy who bought the rights to a drug called Daraprim, hiked the prices, and spent a few years in Federal prison for securities fraud and conspiracy.

Shkreli is now an investor who co-founded several hedge funds, including Elea Capital, MSMB Capital Management, and MSMB Healthcare. He is also known for his frank, blunt, and straightforward responses on X.

His LinkedIn currently shows he is the Co-Founder of DL Software Inc.

One of his most recent posts on X criticized those who choose to short Tesla stock, stating he does not understand their perspective. He gave a list of reasons, which I’ll link here, as they’re not necessarily PG. I’ll list a few:

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  • Fundamentals always have and will always matter
  • TSLAQ was beaten by Tesla because it’s “a great company with great management,” and they made a mistake “by betting against Elon.”
  • When Shkreli shorts stocks, he is “shorting FRAUDS and pipe dreams”

After Shkreli continued to question the idea behind shorting Tesla, he continued as he pondered the mentality behind those who choose to bet against the stock:

“I don’t understand ‘TSLAQ.’ Guy is the richest man in the world. He won. It’s over. He’s more successful with his 2nd, 3rd, and 4th largest companies than you will ever be, x100.

You can admit you are wrong, it’s just a feeling which will dissipate with time, trust me.”

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According to reports from both Fortune and Business Insider, Tesla short sellers have lost a cumulative $64.5 billion since Tesla’s IPO in 2010.

Elon Musk issues dire warning to Tesla (TSLA) shorts

Shorts did accumulate a temporary profit of $16.2 billion earlier this year.

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Tesla will let you bring back this removed Model 3 part for a price

It will cost $595 and is available on Tesla’s website. You will have to have a Model 3 on your Tesla account to purchase the stalk retrofit kit.

Published

7 hours ago

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October 8, 2025

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Credit: Tesla Asia/X

Tesla is now letting Model 3 owners in the United States bring back one part that the company decided to remove after it refreshed the all-electric sedan last year. Of course, you can do it for a price.

With the Model 3 “Highland” refresh that Tesla launched last year, one of the most monumental changes the company made was to ditch the turn signal stalk altogether. Instead, Tesla opted for turn signal buttons, which have been met with mixed reviews.

I drove the new Tesla Model 3, here’s what got better

The change was widely regarded as Tesla preparing for more autonomous driving in its vehicles, especially as its interiors have gotten even more minimalistic.

The lack of a stalk in the new Model 3 was just another move the company made to adjust drivers and passengers to seeing less at the steering wheel column.

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However, many drivers did not prefer the use of buttons and wanted the stalk reinstalled. Tesla allowed it in several regions, launching a retrofit kit. It has now made its way to the United States:

It will cost $595 and is available on Tesla’s website. You will have to have a Model 3 on your Tesla account to purchase the stalk retrofit kit.

It is interesting to note that despite Tesla’s strategy to remove the stalk with the new Model 3, which was released in early 2024, the company did not choose to make the same move with the new Model Y.

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The new Model Y launched in the United States in early 2025, and Tesla chose to install a stalk in this vehicle.

It seemed as if the turn signal buttons were too much of a polarizing feature, and although the company technically could have given orderers an option, it would not have been the most efficient thing for manufacturing.

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Tesla Full Self-Driving v14.1 first impressions: Robotaxi-like features arrive

Tesla Full Self-Driving v14.1 is here, and we got to experience it for ourselves.

Published

8 hours ago

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October 8, 2025

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Tesla rolled out its Full Self-Driving v14.1 yesterday, its first public launch of its most robust and accurate FSD iteration yet. Luckily, I was able to get my hands on it through the Early Access Program.

The major changes in FSD v14.1 were revealed in the release notes, which outline several notable improvements in areas such as driving styles, parking, and overall navigation. Here’s what Tesla outlined fully in its release notes:

  • Added Arrival Options for you to select where FSD should park: in a Parking Lot, on the Street, in a Driveway, in a Parking Garage, or at the Curbside.
  • Added handling to pull over or yield for emergency vehicles (e.g. police cars, fire trucks, ambulances).
  • Added navigation and routing into the vision-based neural network for real-time handling of blocked roads and detours.
  • Added additional Speed Profile to further customize driving style preference.
  • Improved handling for static and dynamic gates.
  • Improved offsetting for road debris (e.g. tires, tree branches, boxes).
  • Improve handling of several scenarios including: unprotected turns, lane changes, vehicle cut-ins, and school busses.
  • Improved FSD’s ability to manage system faults and recover smoothly from degraded operation for enhanced reliability.
  • Added alerting for residue build-up on interior windshield that may impact front camera visibility. If affected, visit Service for cleaning!

I wanted to try it for myself. My big must-dos were my complaints with v13.2.9, which included parking when arriving at a destination, Navigation when leaving a destination, and definitely a general improvement in the car traveling at an acceptable rate of speed, even when using the “Hurry” driving style.

Here’s what I noticed with the new Full Self-Driving v14.1:

Speed Profiles are More Realistic

I am driving on “Hurry” about 95% of the time when utilizing Full Self-Driving. In past versions, most notably v13.2.9, my Tesla would slowly reach the speed limit, and it would tend to hang out at about 1-2 MPH either above or below it.

My first observation with v14.1 was the vehicle’s tendency to get right up to speed and, since I was still on Hurry, drive slightly above the speed limit. It never got out of line; it traveled at speeds I would typically drive at manually.

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I think this is a big improvement on its own, because I felt that I was pressing the accelerator too frequently in past FSD versions. Oftentimes, it just wasn’t going fast enough to justify the “Hurry” label; it felt more conservative and more like a student driver than anything.

Check it out:

This was among my favorite improvements, and it was the first thing I noticed as the car navigated me to the Supercharger, where my next positive is.

Navigating into parking lots, self-parking at Supercharger

One of the changes noted in the Release Notes was the addition of Arrival Options, which allows the car to select the appropriate parking situation. Since I was going to charge, the car had already chosen “Charger” as the parking option.

Pulling into a gas station or convenience store, especially during work days, can be stressful, as they are usually congested and full of foot and vehicle traffic. In past FSD versions, I have noticed the car being slightly “jumpy” and even hesitant to proceed through the lot.

Driving through parking lots was a noticeable improvement. It seems as if the car is much more confident in making its way through, while still being aware and cautious enough to safely navigate to the Supercharger.

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It then backed straight into a Supercharger stall, which was recently repaired and is once again active. I was actually upset it chose this specific stall because it had been inactive for a while. However, Tesla got this stall back up and running, the car chose it, and backed into the spot flawlessly:

This was super cool to experience, and I think it is a testament to how hard the Tesla AI team has worked. CEO Elon Musk recently stated that FSD would enable automatic parking at Superchargers, which was really awesome to experience firsthand.

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I decided to leave the Supercharger and go to an auto parts store to pick up some interior cleaner and some microfiber towels. I love keeping my Tesla clean!

I also thought it would be a great opportunity to see how it would react to another parking lot, how it would navigate it, and let it choose a parking spot. It did it all flawlessly:

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I had zero complaints about everything here. All of it was done really well.

Making a choice after being caught in the middle of an intersection

I arrived at a tight intersection in Dallastown, PA, and what my car did next has catalyzed quite a conversation on X.

It proceeded out into the middle of the intersection as the light was green. It had to yield to oncoming traffic, and while waiting, the light turned yellow, then red.

Most people, including myself, would have turned right and proceeded through the intersection since the car was already past the line. However, FSD chose to back up and wait for the next light cycle, which I felt was also a more than acceptable option:

There are some conflicting perspectives on what it chose to do here. Some said they would have proceeded and would want FSD to also proceed. I can agree with that perspective, but I also think it is not the worst thing in the world to back up. In Pennsylvania, I couldn’t find the exact law that says what is right or wrong. Instead, I did see that a left turn on red is only feasible when you’re going from a One-Way street to another One-Way.

I’m not totally sure what is “correct” here, but I think either option is fine. I have personally done both, and I’ve seen other drivers do both. I was more than fine with the car doing this, and I was honestly impressed that it did.

Navigated a busy grocery store lot, found suitable parking

This is not the busiest my local grocery store gets, but it was still congested enough for me to be impressed.

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FSD decided to do one loop in the parking lot before it found a spot that it felt was good enough for me. I was perfectly fine with where it chose to park, and I thought it did a really great job. I was impressed with how stress-free I felt, as I have noted in the past that parking lots are definitely an area where Tesla needs to improve.

I was happy with its performance:

Strange right turn signal as if it saw an emergency vehicle

This was the first bug I noticed with FSD v14.1. While traveling on a local road, it put the right turn signal on and approached the curb as if it was pulling over for an emergency vehicle or as if it was going to park on the street.

It then realized its mistake and proceeded:

I’m not super sure what caused this, but I was a tad bit confused. There were no police cars, ambulances, or anyone with flashing lights to my rear. There was a dump truck on the other side of the road, and I almost felt like the way it navigated “around” that was probably what triggered it.

Navigation is still making strange decisions

I’ve written about navigation and my discontent with some of its decisions. It seems v14.1 didn’t resolve much of anything with navigation, and it did a couple of things wrong.

The first was that it tried to take the illogical and pointless path out of the Supercharger. I wrote about this a few days ago, as FSD tried to take my car the wrong way.

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It did it again, but I overrode the decision, and it was all okay:

This is a minor issue, but it is still pretty frustrating. Hopefully, the navigation will learn after performing this adjustment after enough times.

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The next navigation issue was more frustrating than the Supercharger one, especially considering it completely ignored the route. The navigation had the vehicle very clearly heading straight, but out of nowhere, the right turn signal went on. I overrode it, but the car still turned right, ignoring the navigation completely:

I ended up taking over here and driving until I could get to a stop sign.

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Final Thoughts

I am really impressed with all of the changes Tesla made with FSD v14.1, and while there were a handful of bugs, things were tremendously better than v13.2.9.

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