Tesla Door Handle Concerns Could Lead to New U.S. Vehicle Safety Rules

U.S. auto safety regulators have begun a rulemaking process that could lead to new safety standards requiring automakers to ensure drivers and passengers can safely exit vehicles during emergencies. The move follows a series of incidents, including fatal crashes, in which occupants became trapped inside vehicles equipped with flush, electronically operated door handles, including some Tesla models.

The National Highway Traffic Safety Administration (NHTSA) announced the decision in response to a petition requesting a safety defect investigation into the emergency mechanical door release system on 2022 Tesla Model 3 vehicles. Petitioners argued that the design does not comply with federal motor vehicle safety standards.

Rather than opening a defect investigation, NHTSA said the issue would be more appropriately addressed through the federal rulemaking process, which could eventually establish new industry-wide safety requirements.

Rulemaking process begins

NHTSA emphasised that approving the petition does not mean a new regulation will automatically be adopted. Instead, the agency will collect additional data, seek public feedback and determine whether a new safety standard is warranted under the Vehicle Safety Act.

If new rules are ultimately introduced, they would apply to all automakers rather than targeting a single manufacturer.

Tesla door handles under scrutiny

The decision follows an investigation launched by NHTSA last year after receiving multiple reports from Tesla owners who said they were unable to open their vehicles, in some cases while children remained inside. The review also followed reports of drivers and passengers becoming trapped after crashes.

Although Tesla vehicles include manual interior door releases, they are located inside the cabin. NHTSA previously noted that the electronic door handle system may fail if thevehicle’ss battery does not provide sufficient voltage after a collision or power loss.

Automakers considering design changes

Tesla designer Franz von Holzhausen said last year that the company was working on a redesign of its door handles. Rivian has also announced changes to the interior door release on its upcoming R2 SUV, placing the manual release in a more visible position closer to the electronic handle.

The rulemaking process marks another step in the government’s broader review of electronic door handle safety as more automakers adopt flush, electronically operated designs on modern vehicles.