Potts' Stark-tech armor suit, which is designated Mark 1616, but named Rescue by Potts, represents a Hybrid of repulsor Technology and portable electromagnetic super-field generators that give the suit FLIGHT, speed, strength, and magnetic-field manipulation. Its electromagnetic force fields are powerful enough to enable Rescue to stop a falling jet airliner without physical contact with it, and can also be used as an offensive weapon with other armored opponents. The suit's physical strength enables it to hold up a stilt mansion felled by an earthquake, and to rip the lower leg of the Black armor. The armor also features an artificial intelligence named J.A.R.V.I.S. that acts as a guide for Potts. During the 2012 storyline "The Future", Potts and Carson Wyche come to suspect that J.A.R.V.I.S. has been compromised, and when they attempt to troubleshoot the Rescue helmet, J.A.R.V.I.S. takes control of the Rescue armor, and takes Potts and Wyche hostage. J.A.R.V.I.S. is disabled by James Rhodes with a source-focused electromagnetic pulse from the Black armor, and is eventually destroyed by Potts, ending her career as Rescue. She has a new Rescue armor in the subsequent series Superior Iron Man, armed with sonic disruptors.

Virginia "Pepper" Potts first appeared in Tales of Suspense #45 (Sept. 1963), which was written by Stan Lee and illustrated by Don Heck. Though she was named Pepper Potts from the start, Stark addresses her as "Kitty" in one panel, which is thought to be a typo. Heck modeled Potts as Ann B. Davis’ character of Schultzy from The Bob Cummings Show, and is rendered with brown hair done up in a hairdo similar to that of Schultzy's. Someone on the creative team or in editorial came to feel that the resemblance was too great, and in Tales of Suspense #50, Potts' look was altered to give her red hair and a different hairdo.

After Happy sustains massive injuries in a fight with Spymaster during the 2006-2007 "Civil War" storyline, Pepper requests that Tony turn off Happy's life support (using his Extremis abilities). The final pages of Invincible Iron Man vol. 4, #14 shows the death of Happy.

When Tony is blamed for the Skrull invasion of Earth that occurs in the 2008 storyline "Secret Invasion", S.H.I.E.L.D. is taken over by Norman Osborn, replaced with H.A.M.M.E.R., and Stark and Maria Hill are fired, along with all of S.H.I.E.L.D.'s employees. Tony realizes that Osborn is after the identities of superhumans that registered with the government following the passage of the Superhuman Registration Act that occurred during the "Civil War" storyline, which is stored in a database in his brain. Stark decides to go underground with Hill, and to wipe the knowledge in his own brain. Stark makes Pepper the new CEO of Stark Industries, trusting only her to shut down the company in his absence. Pepper discovers a secret room in Stark's office which contains a suit of armor that he made especially for her, which she uses under the name Rescue. Though Osborn has seized all Stark Industries facilities and equipment, Pepper states that all components of her armor are legal and that the design specifications are available to anyone. Despite Osborn threatening her loved ones with prison if she interferes with his search for Tony or attempts any more heroic actions, after being freed she endeavors to find Tony herself. They are reunited in Russia, and consummate a now-sexual relationship, but are subsequently captured and tortured by Madame Masque, who was assigned by Norman Osborn to track Stark down. Stark admits that he had loved Masque in the past, but when pressed to make a choice, with his own life on the line, Tony chooses Pepper. Pepper decides to engage Masque in a physical altercation in order to provide a distraction for Stark to escape.

During the 2009 "World's Most Wanted Storyline" (which ran concurrently with Marvel's company-wide storyline "Dark Reign"), Pepper, after defeating Masque, disguises herself as the former, infiltrating H.A.M.M.E.R. while presenting the Rescue armor to Osborn as spoils of battle. Pepper reveals herself when she rescues Black Widow and Maria Hill from Osborn's imprisonment, while the Rescue suit uploads a virus into H.A.M.M.E.R.'s computers, taking control of the Helicarrier's armory of suits. They then retrieve the hard drive that Hill was assigned by Stark to get, escaping to give it to Captain America in order to restore Starks' mind. As part of "re-booting" Tony (in a vegetative state), the magnet in her chest is removed and placed into his.

During the 2011 "Stark Resilient" storyline, when Justine Hammer and Sasha Hammer use their own armored enforcer Detroit Steel to attempt to sabotage Stark Resilient (Tony's new company) and its design for a repulsor technology-powered vehicle, Pepper joins War Machine in helping Stark, during which Pepper experiences a near-death experience in which JARVIS, masquerading as Happy, gives Pepper a cryptic warning of the Future.

In the 2012 storyline "The Future", Pepper returns to her civilian life following her destruction of J.A.R.V.I.S., the artificial intelligence that helped her control her Rescue armor, after its compromise led it to go rogue and attempt to kidnap her. She became engaged to Marc Kumar, a public relations and marketing consultant, but broke off the relationship after he briefly became a supervillain.

The Stark-tech mag-field generator implanted in Pepper’s chest was not weapons-based like Stark's, but borrowed non-weaponized electromagnetic Technology from Rand Industries, which caused a number of physical changes to her body. It cured her tinnitus, improving her hearing. It allows her to sense electromagnetic fields, and manipulate them to levitate her body.