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As competition in the EV market intensifies, automakers must focus on lean manufacturing and integrated drive units to boost performance, reliability, and cost efficiency. In this focused teardown discussion, Munro & Associates sits down with Rivian CEO RJ Scaringe to break down the company’s new dual motor system called “Enduro.” Together, they examine its design, cost advantages, and real-world performance. This dual motor platform doesn’t just replace the quad motor for some customers. It signals a new direction in EV drivetrain strategy.
Vertically Integrated for Performance and Control
Rivian’s Enduro dual motor system stands out for its complete vertical integration. RJ Scaringe explained that Rivian builds everything in-house, from the rotor and stator to the hairpin windings, at its Normal, Illinois facility. This approach gives the company full control over manufacturing tolerances, material selection, and quality. It also reduces reliance on outside suppliers, cutting cost and complexity in the process.
Performance stays strong. The quad motor delivers 835 hp and 908 lb-ft of torque. In comparison, the dual motor system still packs a punch with 665 hp and 829 lb-ft. On the road, Sandy Munro reported almost no noticeable difference in acceleration. The 0–60 mph time is only about 0.2 seconds slower—barely enough to feel.
Efficiency and Range Upgrades
One of the most tangible benefits of the new drive unit is increased range. With a large battery pack, the dual motor version now boasts an EPA-estimated range of 352 miles—a clear improvement over the quad’s 328-mile rating. This enhancement comes from better thermal efficiency, a lighter design, and refined drive unit architecture.
Rivian’s intelligent drive mode software dynamically disconnects the rear drive unit under light load or highway cruising conditions, improving overall efficiency by approximately 5%. This front-only drive strategy preserves torque when needed but reduces energy consumption when it isn’t. At speeds under 20 mph, the rear unit remains engaged for better traction. Above that, the system disengages unless reactivated by throttle demand.
A Purpose-Built Coolant and Ceramic Bearings
Rivian’s Enduro unit also debuts a custom oil-based dielectric coolant. Rivian co-developed it with a supplier to meet both thermal and electrical insulation needs. Unlike standard transmission fluids, this coolant handles submerged operation with ease. It allows the drive unit to perform reliably in deep water and extreme conditions.
Another feature is the use of ceramic ball bearings, which offer reduced friction, improved durability, and reduced electromagnetic interference (EMI). While ceramic bearings don’t conduct electricity, Rivian added EMI brushes as part of a redundancy strategy to meet aggressive lifetime and durability targets.
Inverter Integration and Manufacturing Strategy
Rivian’s drive unit uses a 3-in-1 architecture—integrating the motor, gearbox, and inverter into a compact, vertically assembled unit. This design minimizes reorientation on the production line, enabling faster robotic assembly and reducing labor costs.
RJ noted the switch from Danfoss power modules to Infineon’s three-pack units. These allow for flexibility between silicon carbide (SiC) and silicon IGBT semiconductors. While SiC offers better efficiency, especially at high voltage, IGBT components provide a significant cost advantage for fleet and commercial applications. This dual-path approach makes the supply chain more robust and scalable for future vehicle platforms, including the R2 series and commercial delivery vans.
Coated Inverter Housings and Advanced Sealing
One curiosity in the teardown was Rivian’s choice to coat the inside of the inverter housing—a rare move in the industry. Scaringe explained this was to ensure long-term corrosion resistance, particularly since the drive unit is engineered for submerged operation. The coating and sealing strategy also contribute to the system’s extreme durability, targeting a lifetime of off-road use with high exposure to mud, water, and temperature extremes.
Resolver Size and Hairpin Excellence
Munro praised Rivian’s compact resolver, which performs as well, or better, than much larger competitors. The hairpin stator design also earned high marks. With only one side requiring welds and the other side relying on simple braiding, Rivian’s approach maximizes manufacturing efficiency and reduces potential failure points.
RJ highlighted how the automation process enables precise hairpin insertion with optimized bend radii, maintaining tight tolerances across the stator’s geometry. Compared to other OEMs, Munro ranked Rivian’s hairpin execution as among the best—second only to one unnamed competitor.
Disconnect Strategy and Software Tuning
The dynamic rear axle disconnect in the dual motor R1 models is software-controlled. Unlike the original “Conserve Mode” that required manual activation, the new system uses sensors and torque demand to seamlessly connect or disconnect the rear drive unit in real time.
This means no harsh re-engagement or noise when torque is reapplied. RJ shared how engineers spent extensive time refining the transition curve using laptops in-vehicle, ensuring a smooth, imperceptible handoff between drive modes—important for customer satisfaction and NVH control.
Cost Savings and Remanufacturing
Perhaps the biggest selling point for the Enduro platform is cost. Rivian confirmed the dual motor drive unit offers a greater than 25% reduction in cost compared to the quad motor setup. These savings stem from internalizing stator/rotor production, consolidating assemblies, and simplifying component mounting.
Rivian expects strong production volume for the Enduro platform. It will power all of the company’s commercial vans. It’s also projected to account for over half of R1 vehicle output. Looking ahead, Rivian is already developing a second-generation version. This updated design will simplify the bus bars and improve how the power module mounts.
The platform also considers remanufacturing, with Rivian operating a dedicated facility in Kentucky for rebuilding drive units from collision-damaged or end-of-life vehicles.
Final Thoughts and Teardown Expectations
From a teardown perspective, Munro’s team highlighted areas of possible overdesign—such as the internal bus bar network—but commended Rivian’s strides in manufacturability and cost efficiency. RJ welcomed the feedback, noting several of these elements are already targeted for simplification in the next-gen design.
Rivian’s new dual motor R1 system isn’t a downgrade from the quad. It’s a complete rethink of the electric drivetrain. The design is lean, powerful, modular, and built for mass production. It also offers better range, improved real-world efficiency, and smart, software-driven features. With all that, the Enduro drive unit stands out as Rivian’s most advanced—and most practical—system to date.
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