In 2016, the figure saw re-release with the Combiner Force packaging. Being the tenth use of the sculpt at this point, some instances of mold deterioration have affected the figure, including: the vehicle front's bumper (which affects the space on the head/front bumper transformation), the headlights, and/or the legs, and the hole on the left shoulder is also prone to develop a stress mark due to the right shoulder's slightly "thickened" peg. Although the re-released badge didn't seem to unlock Optimus Prime after it was scanned, a later update to the game amended this.
Optimus Prime returns in Transformers: Revenge of the Fallen. He leads the Autobots as part of NEST in hunting down the remaining Decepticons on Earth. He later engages in a battle with Starscream, Grindor, and a resurrected Megatron. Although Optimus manages to injure Starscream and kill Grindor, he is eventually impaled and killed by Megatron. However, Optimus is resurrected during the battle in Egypt by Sam using the Matrix of Leadership. He is then fused with the dead body of Jetfire, giving him an extremely powerful upgraded mode. After severely maiming Megatron, he kills The Fallen, forcing Megatron and Starscream to retreat. At the end of the film, Optimus thanks Sam for reviving him and again transmits a message to space, hoping to find more Autobots.
Like several new-mold Revenge of the Fallen toys, Optimus Prime suffers from some cost-cutting measures that affected the final production version of the mold. According to Hasbro's stock photos/back-of-box photo of the hand-painted prototype, the toolboxes on the sides of his legs were designed to fold away further for a sleeker, cleaner look. Additionally, the rear tires would have been able to split in half, with the inner half of the tire going inside the outer half to recreate the thin tires seen on Prime's CG design. Some articulation was lost on the toy between Hasbro stock photography and the final release. His fingers are no longer articulated; instead, the entire hand is now one molded piece. Finally, the lower arms appear to have been originally designed so that his hands could slide in or out of them during transformation. Sadly, he also lacks rubber tires, which the original movie Prime did have. Meanwhile, the articulated fingers was later used for the Asia Premium Series & Movie The Best releases.
In robot mode, like Combat Hero Prime, the bottom of the truck became his familiar windowed chest based upon the original Optimus Prime toy. His main gimmick was light up LED headlights, and a lightpipe in the bottom of his right fist, illuminated by an LED in his right forearm, that would illuminate his clear sword or his double-barreled rifle if they were used in that hand. All three LEDs were activated simultaneously by pressing the sunroof-like depression on the roof of the truck.