Over 4 million cars – almost all Teslas – are being recalled in China after the government banned hidden door handles that could leave passengers trapped in emergency situations. The move follows a patch of incidents in which sleek, recessed door handles failed to open when power was lost.
Hidden handles, popularised by Tesla and other electric‑vehicle manufacturers, look clean but can be hard to locate. When batteries fail or a crash disables electronics, the interior of the car may be locked shut, with no mechanical release to pull the door open. In 2025, two fatal crashes involving Xiaomi’s SU7 were blamed on a similar design problem.
China’s new regulations, effective 1 January 2027, require that every door have a mechanical exit both inside and outside. Manufacturers must also add warning labels inside vehicles explaining how to open the doors in an emergency. The rule was the first of its kind; it is expected to spread to other markets, including the United States and the European Union.
The State Administration for Market Regulation has ordered Tesla to recall nearly three million Model S, Model 3, Model X and Model Y vehicles, and Xiaomi, XPeng and Geely will send back more than 750,000 cars. The recall covers doors whose handles are a nearly indistinguishable colour to the interior trim, making them difficult to find and even harder to operate if power is lost.
In the United States, Tesla has faced several lawsuits after a 2024 Cybertruck crash in California left three college students dead because the electronic door‑open buttons failed. The design has drawn criticism that “you are betting the electronics will work in every scenario, including a high‑speed crash followed by a fire.” Tesla officials claim the Cybertruck meets federal safety standards.
Regulators in the U.S. and Europe are now reviewing potential requirements to ensure concealed door handles remain functional without power. Engineering experts argue that a mechanical release is still the safest solution.
The recall highlights the tension between style and safety in modern automotive design and underscores the need for clear emergency exit systems as electric vehicles grow in popularity worldwide.
