What we know about the door handles that triggered China's record auto recall

Electronic door handles of the kind that are at the centre of China's largest-ever vehicle recall have proliferated across the globe over the past decade, especially on electric vehicles.

Tesla and eight other automakers said on Friday (21 August) they will recall a total of about 4.3 million vehicles in China over concerns that their doors may be difficult to open in an emergency.

Popularised by Tesla, the door handles are designed to sit flush to the body of the door, for a minimalist look that also reduces aerodynamic drag. The handles electronically extend outwards, typically as the owner approaches the car. It is unclear whether Tesla plans to do a similar recall in the US or Europe. The company and auto-safety regulators in the US and Europe did not immediately respond to requests for comment.

What are the concerns with these handles?

Vehicle doors with these handles employ buttons to open them rather than a traditional mechanical system. If automakers do not have a clear manual release option for if a car loses power, it can be difficult for passengers or the driver to escape a vehicle in a life-threatening situation, said Michael Brooks, executive director of the Center for Auto Safety.

While some automakers have a relatively intuitive system in which an interior lever can be pulled twice to manually release, Tesla's manual release is either in the door pocket or under a panel, without clear signage, he said.

What do car owners think?

Some EV drivers have found the evolving design of high-tech handles confusing.

"The basic touch point of door handles is now a percolating problem area as manufacturers attempt to redesign them," consultants JD Power said in 2023, stating that seven of the 10 most problematic models in this area were EVs.

Several lawsuits have alleged that Tesla's door-handle designs led to driver or passenger injuries or deaths after they were trapped in a vehicle while it was on fire. Some drivers have also complained to the US National Highway Traffic Safety Administration about being unable to get their child out of a vehicle after exiting.

What vehicles are involved in the recall?

Tesla and several other automakers, including Xiaomi, launched software updates on Friday and said they would recall nearly 4.3 million vehicles over concerns it may be difficult to open doors in an emergency. Leapmotor, Xpeng and Geely also announced their largest recalls on record.

Reuters was unable to get an exact count of models using these electronic handles globally, but automakers have rolled out the design on dozens of new EV models globally in recent years.

What are regulators doing?

China has increased oversight of the EV industry this year and in February said it would ban "hidden" door handles from 2027, the first country to take this step. In the US, proposed legislation would order cars with this kind of handle to also carry a manual door release that is fail-safe.

The NHTSA said in July that the door release problem should be addressed through potentially creating a new formal safety standard that would apply to all automakers.

The decision came after the regulator reviewed a petition seeking a recall of Tesla Model 3 sedans over concerns that emergency door release controls may not be clear in an emergency. The NHTSA denied the petition in favour of addressing the issue through rulemaking.

Last year, European regulators flagged the potential risks involving door-handle designs as a key priority. The UN Economic Commission for Europe has been drafting new standards to ensure that electronic handles can be opened from inside and out if the car's electricity is cut off.

A recall in one country does not necessarily mean an automaker would do the same in other markets, Brooks said.

"There remains a possibility here that Tesla will fight a recall in the United States," he said.