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Rivian set to debut energy storage project using ‘second life’ batteries from vehicles

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Rivian Automotive and the Honnold Foundation are working together in an initiative that is set to use the electric truck maker’s “second-life” batteries as stationary energy storage units in a microgrid project at Adjuntas, Puerto Rico. This marks a huge step for Rivian, which is planning on expanding its reach beyond the manufacture of all-electric luxury adventure vehicles.

Rivian will be utilizing 135 kWh battery packs from its development vehicles for the upcoming energy storage project, which is expected to launch in 2020. The company has designed its battery packs and modules in such a way that they can be easily transitioned from vehicle energy storage to stationary energy storage at the end of their vehicle life. The Rivian CEO described the concept in a press release.

“Second-life batteries are a big enabler to accelerating widespread adoption of renewable energy, and it’s exciting to envision this system contributing importantly to a community. This project allows us to model a customized energy storage solution that takes into account space constraints, disaster resiliency, and energy independence,” Scaringe said.

Using older batteries for energy storage is a clever way for Rivian to recycle the cells it uses for its all-electric trucks. While batteries at the end of their vehicle life will likely show some wear compared to those used in new EVs, they could still function well as stationary energy storage units. After all, optimal batteries for electric trucks require a lot of power, but those energy storage units could make do with much less (propelling the R1T from 0-60 mph, for example, takes a lot of power, but turning on the lights in a household does not require as much).

Rivian and the Honnold Foundation selected Adjuntas, Puerto Rico as the site of their microgrid project partly due to the town being in need of help. Adjuntas was struck by Hurricane Maria in 2017, and the community has been struggling with power since. If successful, Rivian and Honnold’s microgrid initiative could help many of the businesses located near the town’s main square. Residents could also have backup power in the event that power shortages happen.

Further details of the project will be discussed by RJ Scaringe and elite climber Alex Honnold at Denver, CO on June 15 in a livestreamed event, which could be accessed here.

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The full press release for Rivian and the Honnold Foundation’s upcoming microgrid project could be accessed below.

DENVER, June 13, 2019 /PRNewswire/ — On June 15, electric adventure vehicle maker Rivian is announcing a project to use its second-life batteries in a solar microgrid initiative with the Honnold Foundation. The goal: to support energy independence and adoption of renewable power generation. The project, in the town of Adjuntas, Puerto Rico, marks Rivian’s first steps in its broad plan to utilize second-life batteries for a wide variety of applications.

Rivian CEO RJ Scaringe and elite climber Alex Honnold will discuss the project in Denver, Colorado on June 15 at 6PM MT. The conversation will be moderated by endurance athlete and podcaster Rich Roll. The livestream can be found here: https://www.youtube.com/c/RivianOfficial/live

The company is using 135kWh battery packs from its development vehicles to support the project.

Rivian has designed its pack, module, and battery management system to seamlessly transition from vehicle energy storage to stationary energy storage at the end of their vehicle life. The battery module’s thin design enables second-life applications that are space-efficient and customizable, important for environments with existing infrastructure.

“Second-life batteries are a big enabler to accelerating widespread adoption of renewable energy, and it’s exciting to envision this system contributing importantly to a community. This project allows us to model a customized energy storage solution that takes into account space constraints, disaster resiliency and energy independence,” said Scaringe.

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Adjuntas is a city of 20,000 in midwestern Puerto Rico. It was severely impacted by Hurricane Maria in 2017, and with climate change increasing the frequency and severity of storms, Adjuntas NGO Casa Pueblo has sought to collaborate on rugged, affordable sources of community power.

The Honnold Foundation and Rivian battery engineers visited Casa Pueblo earlier in 2019 to meet with community leaders and together are designing a site-specific system that will power many of the businesses located in the Adjuntas town square. In power loss scenarios, the downtown solar microgrid will allow Adjuntas residents access to electricity for core businesses. By offsetting day-to-day electric bills, the system also brings down high commercial energy costs, which in Puerto Rico are twice the national average.

The system is expected to launch in 2020.

Simon is an experienced automotive reporter with a passion for electric cars and clean energy. Fascinated by the world envisioned by Elon Musk, he hopes to make it to Mars (at least as a tourist) someday. For stories or tips--or even to just say a simple hello--send a message to his email, simon@teslarati.com or his handle on X, @ResidentSponge.

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Starlink is ‘biggest competitive advantage,’ but it’s temporary, United CEO says

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Credit: United Airlines

United Airlines CEO Scott Kirby said that SpaceX’s Starlink satellite internet is its leading competitive advantage in the U.S. airline industry. However, in recent comments, while he described the service as “the biggest competitive advantage” the carrier currently holds, he also acknowledged that the edge is temporary.

“…everybody eventually is going to have high-speed low earth orbit internet connectivity. It’s going to be a must-have. We are going to have a few years of being the only airline that has it at scale, and that’s our mission,” Kirby said. Until everyone has it, United aims to capitalize on its head start by converting trial users into long-term loyal customers.

United has moved faster than its rivals on Starlink installations. As of mid-to-late October 2026, the system was on roughly 43 percent of its fleet, with plans to reach 61 percent by year-end, 87 percent by June 2027, and full fleet coverage by the end of next year.

The airline already operates more Starlink-equipped flights than the rest of the U.S. industry combined. Los Angeles International Airport is scheduled to become United’s first 100 percent Starlink hub in the first half of 2027, and the carrier’s app will display the likelihood that any given flight has the service.

Kirby has pointed to early evidence that the offering influences booking decisions. Some passengers loyal to other airlines are already switching flights for Starlink connectivity, something the airline, along with American Airlines, has tried to leverage against competing airlines. Both companies used status-match programs, and some of those customers are pursuing company-specific credit cards, which signals an intent to stay.

Once onboard, these customers encounter the airline’s broader investments in aircraft, larger seat-back screens, oversized bins, connection tools, and a mobile app that Kirby says outperforms competitors. Wi-Fi satisfaction scores on Starlink-equipped planes have been reported to be nearly double those on aircraft with other systems.

Competitors are moving slowly to do the same. Southwest Airlines began installations in 2025 and expects to complete them soon. Delta is pursuing Amazon’s Leo system, while American expects to start Starlink work in early 2027 and has not yet detailed regional-fleet plans. This timeline gap gives United a multi-year window in which it remains the only major U.S. carrier offering Starlink at scale.

Kirby has framed the strategy as pressing that advantage while simultaneously widening gaps in other technology areas so that customers who try United for the Wi-Fi remain for the overall experience.

The approach reflects a calculated bet that superior in-flight connectivity can accelerate share gains and support longer-term financial targets, including a 10 percent pre-tax margin goal.

High-speed internet is particularly valued by premium and business travelers who can work or stream reliably. As low-Earth-orbit service becomes ubiquitous, the temporary nature of the pure connectivity edge means United’s retention will depend on whether its other product and operational improvements keep pace.

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Tesla Cybercab’s unorthodox paint process explained

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Credit: Tesla

Tesla Cybercab skips the traditional paint shop entirely, marking an unorthodox process for coloring the fully autonomous vehicle. However, the decision was a smart one, as it slashed factory costs, floor space utilization, and complexity, since Tesla relied on specialized alloys and in-mold coloring.

Munro Live was given the opportunity to do a factory walkthrough with Tesla Vice President of Vehicle Engineering Lars Moravy, who explained and detailed how Cybercab production at Giga Texas eliminates one of the automotive manufacturing industry’s most expensive and space-hungry elements.

A conventional paint line can cost hundreds of millions of dollars and require a million man-hours to build. Moravy framed the choice around Tesla’s core rule: “Question the requirements: why do you need paint?”

The structural answer lies in material selection. The aluminum alloys used in Cybercab’s front and rear castings do not oxidize and lose strength over time, the way many common automotive aluminum alloys do. Only the side modules, built around hot-stamped boron-steel door rings, receive an anti-corrosion e-coat, or dip coat. Front and rear modules skip coating altogether.

Model Y and Model 3 bodies, by contrast, are fully coated and painted.

Exterior colors come from the plastics shop, which Tesla engineers described as “our paint shop” for the Cybercab. Body panels are produced via reaction injection molding, referred to as RIM. Color is then mixed into a polyurethane resin at the mix head immediately before injection, so the panel emerges already colored with a Class-A surface.

Robots trim overflow to control sink marks and flow lines. The process avoids conventional spray-paint defects like orange peel and paint bleed. Scratches can still be repaired with compatible coatings that behave “basically like paint.” Because color is integral rather than a surface layer, shallow scratches do not expose a contrasting undercoat.

The secret behind Tesla’s Cybercab Gold goes well beyond just the color

Tesla has also explored related approaches, including in-mold lamination and painted films on stamped panels.

The manufacturing payoff is substantial because removing the paint shop, combined with the “unboxed” modular process that builds and tests front, rear, side, and center modules in parallel before a short final assembly, cuts factory floor space per vehicle by about 50 percent.

Final assembly itself uses only about 25 automated stations, far fewer than the typical Model Y line, and the overall line runs at about 78 percent automation, Moravy said. The approach also eliminates volatile organic compound emissions associated with traditional spray painting for these panels and shortens the coloring cycle from hours to minutes.

Cybercab’s paint strategy is clearly less about aesthetics than about systematically deleting capital-intensive, energy-heavy, and space-consuming steps once material science and process design make them unnecessary. It is a concrete example of Tesla applying first-principles questioning to one of the auto industry’s most entrenched factory requirements.

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Tesla has a Cybercab problem nobody saw coming

Tesla’s Cybercab line now builds robotaxis faster than Tesla can deploy them, Lars Moravy says.

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Tesla’s Cybercab line in Texas can now build the two seat robotaxi faster than the company can put it into service, according to Lars Moravy, Tesla’s Vice President of Vehicle Engineering. “We don’t run every day because the line can run so fast. It’s currently outpacing our deployments,” Moravy said in a new Cybercab deep dive from Munro Live. “So, it’s a bit of a race right now. Who’s going to go faster? Right now the manufacturing line’s ahead.”

Tesla’s official Robotaxi account shared a Cybercab analysis video on X on Monday, calling it a “Cybercab engineering deep dive.” Moravy’s comments go further than what he told analysts on the Q3 earnings call last week, when he said the Cybercab line’s listed capacity of more than 125,000 units a year undersells what it can actually run.

The tour shows where that speed comes from. Tesla’s unboxed process splits the Cybercab into front, rear, side and center modules that are built and tested on their own before they meet on a short final line. That final line has just 25 fully automated stations, which Tesla’s team estimated is a fifth to a tenth of what a Model Y needs. The full line is about 78% automated, the framing line is already at 100%, and the layout uses roughly 50% less floor space per vehicle. The stated goal is “100% automation in 10 second cycle time,” or one finished Cybercab every 10 seconds.

Tesla also deleted the paint shop. Only the side modules are coated, and the exterior panels get their color inside the molding machine. Engineers said the car is designed to run at least 500,000 miles, which matters for a vehicle that will spend most of its day carrying riders.

The battery got the same treatment. The Cybercab uses an 88S6P pack of 4680 cells in a steel enclosure, a first for Tesla, with each module potted separately so a single failed module can be swapped instead of the whole pack. Wireless battery management boards replace a wiring harness, and new contactors are fast enough to drop the pyro fuse entirely. Tesla’s battery director graded the pack an A minus, compared with a D for the Model Y structural pack and a B minus for Cybertruck. Up front, the drive unit runs an 11:1 gear ratio versus roughly 9:1 on most Teslas, since the Cybercab does not need a high top speed.

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The deployment side is now the bottleneck Moravy described. Tesla had more than 50 Cybercabs working the Formula 1 weekend in Austin, and Texas records show 463 Cybercabs registered. Tesla said on its earnings call that Cybercab service will launch in Dallas next month, and Moravy said the company is aiming to get Cybercabs to customers by the end of 2026. Every unit built so far has gone into Tesla’s own fleet since the line moved into volume production in April.

Munro Live also asked when it could get a Cybercab to tear down. Tesla’s answer: “Not yet.”

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