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Inside Rivian’s California battery lab: 180 kWh ‘megapacks’, carbon fiber, and ballistic shields
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 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.
(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.
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.
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- A side view of Rivian’s battery module. Between the two layers of battery cells lies a proprietary cooling plate, allowing cells to be packed in tightly, while cooling the module efficiently. (Photo: Rivian)
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- Rivian Battery modules being tested in Rivian’s Irvine, CA Development Center (Photo: Rivian)
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.
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.
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.
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.”
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.
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Man credits Grok AI with saving his life after ER missed near-ruptured appendix
The AI flagged some of the man’s symptoms and urged him to return to the ER immediately and demand a CT scan.
A 49-year-old man has stated that xAI’s Grok ended up saving his life when the large language model identified a near-ruptured appendix that his first ER visit dismissed as acid reflux.
After being sent home from the ER, the man asked Grok to analyze his symptoms. The AI flagged some of the man’s symptoms and urged him to return immediately and demand a CT scan. The scan confirmed that something far worse than acid reflux was indeed going on.
Grok spotted what a doctor missed
In a post on Reddit, u/Tykjen noted that for 24 hours straight, he had a constant “razor-blade-level” abdominal pain that forced him into a fetal position. He had no fever or visible signs. He went to the ER, where a doctor pressed his soft belly, prescribed acid blockers, and sent him home.
The acid blockers didn’t work, and the man’s pain remained intense. He then decided to open a year-long chat he had with Grok and listed every detail that he was experiencing. The AI responded quickly. “Grok immediately flagged perforated ulcer or atypical appendicitis, told me the exact red-flag pattern I was describing, and basically said “go back right now and ask for a CT,” the man wrote in his post.
He copied Grok’s reasoning, returned to the ER, and insisted on the scan. The CT scan ultimately showed an inflamed appendix on the verge of rupture. Six hours later, the appendix was out. The man said the pain has completely vanished, and he woke up laughing under anesthesia. He was discharged the next day.
How a late-night conversation with Grok got me to demand the CT scan that saved my life from a ruptured appendix (December 2025)
byu/Tykjen ingrok
AI doctors could very well be welcomed
In the replies to his Reddit post, u/Tykjen further explained that he specifically avoided telling doctors that Grok, an AI, suggested he get a CT scan. “I did not tell them on the second visit that Grok recommended the CT scan. I had to lie. I told them my sister who’s a nurse told me to ask for the scan,” the man wrote.
One commenter noted that the use of AI in medicine will likely be welcomed, stating that “If AI could take doctors’ jobs one day, I will be happy. Doctors just don’t care anymore. It’s all a paycheck.” The Redditor replied with, “Sadly yes. That is what it felt like after the first visit. And the following night could have been my last.”
Elon Musk has been very optimistic about the potential of robots like Tesla Optimus in the medical field. Provided that they are able to achieve human-level articulation in their hands, and Tesla is able to bring down their cost through mass manufacturing, the era of AI-powered medical care could very well be closer than expected.
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Tesla expands Model 3 lineup in Europe with most affordable variant yet
The Model 3 Standard still delivers more than 300 miles of range, potentially making it an attractive option for budget-conscious buyers.
Tesla has introduced a lower-priced Model 3 variant in Europe, expanding the lineup just two months after the vehicle’s U.S. debut. The Model 3 Standard still delivers more than 300 miles (480 km) of range, potentially making it an attractive option for budget-conscious buyers.
Tesla’s pricing strategy
The Model 3 Standard arrives as Tesla contends with declining registrations in several countries across Europe, where sales have not fully offset shifting consumer preferences. Many buyers have turned to options such as Volkswagen’s ID.3 and BYD’s Atto 3, both of which have benefited from aggressive pricing.
By removing select premium finishes and features, Tesla positioned the new Model 3 Standard as an “ultra-low cost of ownership” option of its all-electric sedan. Pricing comes in at €37,970 in Germany, NOK 330,056 in Norway, and SEK 449,990 in Sweden, depending on market. This places the Model 3 Standard well below the “premium” Model 3 trim, which starts at €45,970 in Germany.
Deliveries for the Standard model are expected to begin in the first quarter of 2026, giving Tesla an entry-level foothold in a segment that’s increasingly defined by sub-€40,000 offerings.
Tesla’s affordable vehicle push
The low-cost Model 3 follows October’s launch of a similarly positioned Model Y variant, signaling a broader shift in Tesla’s product strategy. While CEO Elon Musk has moved the company toward AI-driven initiatives such as robotaxis and humanoid robots, lower-priced vehicles remain necessary to support the company’s revenue in the near term.
Reports have indicated that Tesla previously abandoned plans for an all-new $25,000 EV, with the company opting to create cheaper versions of existing platforms instead. Analysts have flagged possible cannibalization of higher-margin models, but the move aims to counter an influx of aggressively priced entrants from China and Europe, many of which sell below $30,000. With the new Model 3 Standard, Tesla is reinforcing its volume strategy in Europe’s increasingly competitive EV landscape.
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Tesla FSD (Supervised) stuns Germany’s biggest car magazine
FSD Supervised recognized construction zones, braked early for pedestrians, and yielded politely on narrow streets.
Tesla’s upcoming FSD Supervised system, set for a European debut pending regulatory approval, is showing notably refined behavior in real-world testing, including construction zones, pedestrian detection, and lane changes, as per a recent demonstration ride in Berlin.
While the system still required driver oversight, its smooth braking, steering, and decision-making illustrated how far Tesla’s driver-assistance technology has advanced ahead of a potential 2026 rollout.
FSD’s maturity in dense city driving
During the Berlin test ride with Auto Bild, Germany’s largest automotive publication, a Tesla Model 3 running FSD handled complex traffic with minimal intervention, autonomously managing braking, acceleration, steering, and overtaking up to 140 km/h. It recognized construction zones, braked early for pedestrians, and yielded politely on narrow streets.
Only one manual override was required when the system misread a converted one-way route, an example, Tesla stated, of the continuous learning baked into its vision-based architecture.
Robin Hornig of Auto Bild summed up his experience with FSD Supervised with a glowing review of the system. As per the reporter, FSD Supervised already exceeds humans with its all-around vision. “Tesla FSD Supervised sees more than I do. It doesn’t get distracted and never gets tired. I like to think I’m a good driver, but I can’t match this system’s all-around vision. It’s at its best when both work together: my experience and the Tesla’s constant attention,” the journalist wrote.
Tesla FSD in Europe
FSD Supervised is still a driver-assistance system rather than autonomous driving. Still, Auto Bild noted that Tesla’s 360-degree camera suite, constant monitoring, and high computing power mark a sizable leap from earlier iterations. Already active in the U.S., China, and several other regions, the system is currently navigating Europe’s approval pipeline. Tesla has applied for an exemption in the Netherlands, aiming to launch the feature through a free software update as early as February 2026.
What Tesla demonstrated in Berlin mirrors capabilities already common in China and the U.S., where rival automakers have rolled out hands-free or city-navigation systems. Europe, however, remains behind due to a stricter certification environment, though Tesla is currently hard at work pushing for FSD Supervised’s approval in several countries in the region.
Man credits Grok AI with saving his life after ER missed near-ruptured appendix
Tesla expands Model 3 lineup in Europe with most affordable variant yet
