China Recalls Millions of EVs Over Hidden Door Handle Safety Worries

Retractable door handles, once a standout design feature of electric vehicles (EVs), are now at the center of China’s largest automotive recall, affecting over 4 million vehicles.

The recall involves 2.98 million Tesla vehicles manufactured in China and follows safety concerns that concealed door handles may be difficult to locate and operate during emergencies.

Additional automakers impacted by the recall include XPeng, Xiaomi, and Geely.

Popularized by Tesla CEO Elon Musk’s brand, hidden door handles are designed to blend flush with the vehicle’s door panel, extending only when needed.

However, these designs came under intense scrutiny following two fatal accidents in China involving Xiaomi electric vehicles, where power loss was suspected of preventing door access.

In a statement issued on Friday, Tesla announced the recall of certain Model 3, Y, S, and X variants due to door handles that are challenging to identify and use because their color closely matches the surrounding interior trim.

This poses a risk to occupants and rescue personnel attempting to open doors quickly in urgent situations, including after severe collisions that disable the car’s electrical systems.

To address the issue, Tesla plans to add warning labels to affected vehicles and deploy a software update that will automatically lower windows post-collision.

It remains uncertain whether the involved companies intend to initiate similar recalls globally.

The BBC has reached out to Tesla, XPeng, Xiaomi, and Geely for official statements.

Earlier this year, in February, Chinese regulators introduced new guidelines that will prohibit the use of hidden door handles, effective January 1, 2027. The regulation mandates that all vehicles sold in China must feature mechanical release mechanisms accessible from both the inside and outside of each door.

Additionally, Tesla’s door handle design has been investigated by U.S. safety authorities after incidents were reported where handles failed unexpectedly, trapping children inside vehicles.

In July, the National Highway Traffic Safety Administration in the United States proposed developing a standardized safety protocol requiring all automakers to comply with stricter door handle functionality requirements.

The BBC has also contacted the agency for further information.

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