Explainer-What we know about the door handles that triggered China’s record auto recall

Electronic door handles, a hallmark of Tesla's minimalist design, have become ubiquitous in global vehicle production, particularly on electric vehicles. In a landmark recall, Tesla and eight other automakers announced they would collectively recall about 4.3 million vehicles in China due to concerns over the difficulty of opening these doors in emergency situations.

These door handles, which sit flush against the door body and extend outward when activated, are operated electronically and typically activated when the owner approaches the car.

The design of these door handles, which rely on electronic buttons rather than traditional mechanical systems, has raised safety concerns. If a car loses power, passengers or drivers may struggle to escape the vehicle, potentially leading to life-threatening situations. Michael Brooks, executive director of the Center for Auto Safety, warned that cars without a clear manual release option for power loss could pose significant safety risks.

Some automakers have intuitive manual release systems, but Tesla's require searching the door pocket or under a panel, often without clear signage, making it challenging for users.

The evolving design of these high-tech handles has been noted as a significant problem area, with consultants JD Power reporting in 2023 that seven of the 10 most problematic models in this regard were electric vehicles. Legal actions have been brought against Tesla, alleging that its door-handle designs have led to driver or passenger injuries or deaths in fire-related incidents.

Some drivers have also complained to the U.S. National Highway Traffic Safety Administration (NHTSA) about difficulties in removing children from vehicles after exiting.

In response to these concerns, Tesla and several other manufacturers, including Xiaomi, Leapmotor, Xpeng, and Geely, have launched software updates and initiated a combined recall of nearly 4.3 million vehicles across China. China has stepped up its oversight of the EV industry, announcing a ban on "hidden" door handles starting in 2027.

In the United States, proposed legislation aims to mandate a fail-safe manual door release for vehicles with these types of handles. The U.S. National Highway Traffic Safety Administration (NHTSA) suggested addressing the issue through a new safety standard applicable to all automakers, though it declined a recall petition for Tesla Model 3 sedans in favor of rulemaking.

European regulators also expressed concern over the potential risks of door-handle designs, with the United Nations Economic Commission for Europe working on new standards to ensure electronic handles can be safely opened from inside and outside if a car's electricity is disrupted. While a recall in one country does not guarantee a similar action in other markets, the situation highlights the ongoing challenges in standardizing safety features across global markets.