Tesla Rethinks Flush Door Handles Amid Safety Probes in US and China

Tesla is rethinking one of its most recognisable features: the flush, electronic door handle. Chief designer Franz von Holzhausen told Bloomberg that the company is developing a new version that combines electronic and manual release functions into a single button. 

The idea, he said, is to make escape easier in a panic situation, though he did not say when the decision was made or when the new design might arrive.

The renewed focus comes as American regulators step up scrutiny. The National Highway Traffic Safety Administration (NHTSA) this week opened an investigation into Tesla’s handles after receiving nine recent complaints. 

In four of those cases, owners said they had to smash a window to get in or out of their cars. The probe covers more than 174,000 Model Y SUVs from the 2021 model year and will examine whether the door locks can fail if power is lost.

Tesla’s current system depends on low-voltage power from the battery to operate the electronic latches. While backup manual releases are included, many owners and passengers have found them confusing or hard to reach. Children or people in distress are especially at risk of not being able to locate them quickly.

In China, regulators are also weighing action on flush door handles after a series of complaints and safety studies. Once marketed as aerodynamic breakthroughs, the gains have proven marginal: engineers estimate drag is reduced by just 0.005–0.01 Cd, equal to around 0.6 kWh saved per 100 km, while the motors and support structures add up to 8 kg of extra weight. 

The trade-offs are stark, these handles cost three times more than conventional ones, fail up to eight times as often, and in some cases account for more than 10% of repair claims. Insurance data has shown they can malfunction during accidents, freeze in winter, short-circuit in heavy rain, and even trap people inside.

The problem is not new. Since 2018, NHTSA has logged over 140 complaints tied to Tesla doors, ranging from lock failures to handles becoming stuck. In 2023, Tesla recalled more than 120,000 Model S and X vehicles because the doors could unexpectedly unlatch during crashes.

For Tesla, the redesign could be a way to resolve long-running safety criticisms without abandoning its minimalist aesthetic. “The idea of combining the electronic one and the manual one together into one button makes a lot of sense,” von Holzhausen said. 

Whether that proves enough to satisfy regulators and reassure owners however remains to be seen.