Tesla to Overhaul Door Handle Design Amid Safety Concerns
Tesla plans to redesign its door handles following safety incidents and regulatory scrutiny. The new design will combine electronic and manual release mechanisms into a single, intuitive button. This decision comes after the NHTSA launched an investigation into Tesla's door mechanisms, covering 174,290 Model Y SUVs from 2021, due to over 140 consumer complaints since 2018 about doors malfunctioning. Current design challenges include hard-to-find manual releases and inoperable exterior handles during power loss. Regulatory responses include China considering a ban on fully concealed door handles and Europe implementing improved post-crash rescue protocols.

*this image is generated using AI for illustrative purposes only.
Tesla Inc., the electric vehicle giant, is set to redesign its door handles following safety incidents and regulatory scrutiny. The move comes in response to reports of passengers being trapped inside vehicles due to malfunctioning door mechanisms.
New Design to Enhance Safety
Tesla's design chief, Franz von Holzhausen, has announced plans to combine electronic and manual door-release mechanisms into a single, more intuitive button. This redesign aims to improve accessibility and ease of use, particularly in emergency situations.
NHTSA Investigation
The National Highway Traffic Safety Administration (NHTSA) has launched an investigation into Tesla's door mechanisms. The probe was initiated after receiving over 140 consumer complaints since 2018 regarding doors getting stuck or malfunctioning. The investigation covers an estimated 174,290 Model Y SUVs from the 2021 model year, focusing on incidents where exterior handles stopped working, potentially trapping occupants, including children, inside the vehicles.
Current Design Challenges
Tesla's current door handle design has faced criticism for several reasons:
- Manual releases are placed in locations that can be difficult to find, especially for rear-seat passengers.
- Exterior handles can become inoperable during power loss.
- The flush-to-the-door handles, while aesthetically pleasing, have been said to complicate rescue efforts in emergency situations.
Regulatory Responses
The safety concerns surrounding Tesla's door handles have prompted regulatory actions in different parts of the world:
- China is reportedly considering a ban on fully concealed door handles.
- Europe has implemented measures to improve post-crash rescue protocols.
While Tesla's door design isn't unique in the automotive industry, the company's popularity has brought increased attention to the potential safety issues associated with such designs.
As Tesla works on this redesign, the automotive industry will be watching closely to see how the company balances its innovative design philosophy with critical safety considerations.

























