Rivian R1 Body Structure Extrication B-pillar Rocker

Rivian R1 Body Structure

Below are some pictures from the 2025 Great Designs in Steel presentation from Rivian.

Vehicle Safety Strategy & Crash Performance

Rivian emphasizes meeting rigorous safety criteria (e.g. awards from IIHS) by combining offensive and defensive structural strategies.

“Offensive” structures (those that take primary crash loads) are backed up by a defensive system (pillars, cross‑members) to manage load paths.

Use of press-hardened steel in hinge and A-pillars, reinforced bumper beams, cross-members, and tailored reinforcement help guide the vehicle away from crash barriers and absorb energy.

Body Structure Evolution (Gen1 → Gen2)

• A shift from more aluminum-intensive designs to a greater use of steels (including high-strength and ultra-high-strength steel) in Gen 2 to improve structural efficiency and cost. Am

• Consolidation of parts via advanced manufacturing (e.g. Tailor Rolled Blanks, composite inserts) reduces joining complexity and overall weight. American Iron and Steel Institute

• Optimized joining strategies: reduced reliance on welded reinforcements, more use of strategic thickness variation, structural inserts, adhesive bonding, etc. American Iron and Steel Institute

• Improvements in crash energy management (front, side) by refining rails, crumple zones, cross‑members, bumpers, and so forth.