In a move that signals a significant maturation of the domestic electric vehicle (EV) circular economy, United States-based energy storage provider Redwood Materials and EV manufacturer Rivian have officially launched a strategic partnership to deploy large-scale energy storage systems using "second-life" battery packs. The initiative, centered at Rivian’s massive manufacturing complex in Normal, Illinois, represents a major step forward in addressing the dual challenges of industrial energy demand and battery waste management. By integrating retired vehicle batteries into the factory’s power infrastructure, the two companies aim to create a self-sustaining ecosystem that maximizes the utility of every kilowatt-hour produced.
Under the terms of the agreement, Rivian will supply used EV battery packs that have reached the end of their service life in vehicles to Redwood Materials. Redwood, founded by former Tesla Chief Technology Officer JB Straubel, will then utilize its proprietary Redwood Pack Manager technology to integrate these packs into a comprehensive energy storage system. This system will be deployed on-site at the Normal facility, allowing Rivian to store energy during periods of low demand and discharge it during peak hours. The initial phase of the project is set to utilize more than 100 second-life Rivian battery packs, creating a dispatchable energy resource with a capacity of 10 megawatt-hours (MWh).
The Technology of Second-Life Battery Integration
The concept of "second-life" batteries is predicated on the fact that EV batteries are among the most robust components of modern vehicles. While a battery may lose the high-power density required for the rapid acceleration and long-range demands of a highway vehicle, it often retains 70% to 80% of its original capacity when the vehicle is retired or the pack is replaced. For stationary applications—where weight and volume are less critical than in a moving vehicle—these batteries remain highly effective.
Redwood’s role in this partnership extends beyond mere assembly. The Redwood Pack Manager technology serves as the "brain" of the storage system, monitoring the health and performance of individual cells and modules that may have different degradation profiles. By harmonizing these disparate battery packs into a single, cohesive grid-scale asset, Redwood can provide a low-cost alternative to new lithium-ion storage systems. This approach not only extends the functional life of the battery by a decade or more but also delays the energy-intensive process of recycling until the cells are truly exhausted.
Economic and Grid Implications for Manufacturing
The deployment of a 10 MWh system at a major automotive plant is more than a sustainability gesture; it is a strategic economic move. Large-scale manufacturing facilities like Rivian’s Normal plant are subject to "demand charges" from utility providers—high fees based on the highest level of electricity used during a billing period. By using stored energy from second-life batteries during these peak windows, Rivian can significantly reduce its operational overhead.
Furthermore, the partnership addresses a growing concern in the American industrial sector: grid capacity. As the U.S. shifts toward heavy industry electrification, the existing electrical grid often struggles to keep pace with the power requirements of massive factories. JB Straubel, CEO of Redwood Materials, noted that electricity demand is currently accelerating faster than the grid can expand. By creating "dispatchable" energy resources on-site, companies can bypass the years-long wait times for new utility infrastructure and substations, effectively creating their own microgrids to support growth.
A Chronology of the Rivian-Redwood Relationship
The partnership announced this week is the culmination of years of collaboration between the two firms. The relationship dates back to the early days of Rivian’s production ramp-up, when the companies first explored battery recycling pathways.
- Early 2020s: Rivian and Redwood began an initial recycling partnership, where Redwood processed scrap from Rivian’s battery manufacturing process. This ensured that minerals like nickel and lithium from "off-spec" cells were immediately returned to the supply chain.
- 2023-2024: As the first generation of Rivian R1T and R1S vehicles accumulated significant mileage and some underwent warranty replacements, the volume of available used packs began to grow. The companies initiated pilot testing for stationary storage applications.
- April 2026: The official launch of the 10 MWh second-life project at the Normal plant. This marks the transition from experimental recycling to an integrated, industrial-scale energy management solution.
This timeline illustrates a shift in the industry from a "take-make-waste" model to a "circular" model, where the end of a product’s primary life is merely the beginning of its secondary utility.

Supporting Data and Environmental Impact
The environmental benefits of battery reuse are substantiated by significant data regarding mineral extraction and carbon footprints. Producing a new lithium-ion battery requires the mining of lithium, cobalt, nickel, and manganese—a process that is both capital-intensive and environmentally taxing.
By doubling the lifespan of a battery through a second-life application, the carbon footprint per kilowatt-hour of the battery’s total life is reduced by nearly 40%. Additionally, the 10 MWh system planned for the Normal plant is capable of powering approximately 1,000 average American homes for one hour, or providing the equivalent energy needed to fully charge over 100 new EV battery packs. For an industrial facility, this capacity provides a critical buffer that ensures production continuity during grid fluctuations or brownouts.
Redwood Materials has reported that its recycling processes can recover more than 95% of the critical minerals in a battery. However, the company emphasizes that reuse should always precede recycling. By keeping the minerals in their refined, "active" state within a battery pack for as long as possible, the industry reduces the immediate demand for new mining, which in turn stabilizes the volatile market prices for battery-grade materials.
Official Responses and Strategic Vision
Leadership from both organizations emphasized the broader implications for American competitiveness and energy security. RJ Scaringe, Founder and CEO of Rivian, highlighted the role of EVs as a distributed energy resource. "EVs represent a massive, distributed and highly competitive energy resource," Scaringe stated. He noted that the partnership allows Rivian to contribute to grid health while ensuring that the "American-made" value of their batteries continues long after the vehicle has left the road.
JB Straubel echoed these sentiments, pointing to the strategic importance of domestic battery assets. Straubel, who has long advocated for a closed-loop supply chain, argued that the massive amount of battery material already in the U.S. market is a "strategic energy resource" that can be harnessed to support industrial growth. His vision for Redwood is not just as a recycler, but as a primary materials and energy company that fuels the next generation of American manufacturing.
Broader Industry Impact and Future Outlook
The Rivian-Redwood partnership is likely to serve as a blueprint for other automakers. As the first wave of modern EVs (produced between 2010 and 2020) reaches the end of its typical 10-to-15-year automotive lifespan, the market will soon see an influx of retired batteries. Analysts estimate that by 2030, there will be over 100 gigawatt-hours (GWh) of retired EV batteries available globally for second-life applications.
The success of the 10 MWh project in Illinois could catalyze similar installations at other major manufacturing hubs. Companies like Ford, Volvo, and Toyota—all of whom have existing relationships with Redwood Materials—are watching the Normal project closely. If Rivian can demonstrate significant cost savings and grid reliability, the "factory-powered-by-its-own-batteries" model could become a standard feature of the green industrial revolution.
Furthermore, this partnership strengthens the U.S. position in the global battery race. By developing the technology to manage and reuse batteries domestically, the U.S. reduces its reliance on foreign supply chains for critical minerals. The "Redwood Pack Manager" technology, in particular, represents a high-value intellectual property that ensures the U.S. remains at the forefront of battery software and hardware integration.
As the project in Normal scales, the next step will likely involve the eventual recycling of these second-life packs. Once the 10 MWh system eventually degrades beyond the point of utility for energy storage—likely in the mid-2030s—the packs will be moved to Redwood’s hydrometallurgical recycling facilities. There, they will be broken down into their elemental forms, and the lithium, nickel, and cobalt will be used to manufacture cathode and anode materials for brand-new Rivian batteries. This complete "cradle-to-cradle" cycle represents the ultimate goal of the sustainable transportation movement, ensuring that the transition to electric vehicles is as environmentally responsible as it is technologically advanced.



