Tesla, widely recognized as the first major automaker to introduce electronic door handles in 2012 with its Model S, set a trend. These flush door handles, retracted until the car is unlocked, even had a dedicated webpage explaining their use.

This sleek design element has been adopted by numerous other brands, including Land Rover, Porsche, Kia, and a multitude of Chinese electric vehicle manufacturers.

Flush door handles on a Tesla. Photo: Arena EV

Flush door handles on a Tesla. Photo: Arena EV

Initially praised for its futuristic aesthetic and supposed aerodynamic benefits, the design's impact on drag reduction is minimal according to the Society of Automotive Engineers (SAE). The added 7-8 kg from motors and mechanisms may negate any aerodynamic gains.

Flush door handles are also more expensive than mechanical ones and significantly more prone to malfunctions, increasing repair costs.

The most serious concern is safety. In accidents involving power loss or fire, these handles (both inside and out) can malfunction, hindering rescue and escape.

While front seats typically have a manual release, it took years for automakers to add emergency releases for rear doors. Even then, many rear passengers in Teslas remain unaware of their location or operation.

Chinese electric vehicle Zeekr 001 with flush door handles. Photo: Zeekr

Chinese electric vehicle Zeekr 001 with flush door handles. Photo: Zeekr

There have been numerous instances of injuries and even fatalities linked to these handles. In China, frozen handles in cold weather or short circuits due to heavy rain have trapped passengers, delaying crucial rescue efforts.

Even without accidents, some Tesla owners in the US have resorted to breaking windows to free trapped children, according to a National Highway Traffic Safety Administration (NHTSA) investigation.

On 7/9, a Tesla accident in Germany tragically killed an adult and two children because rescuers couldn't open the doors.

Not only are drivers inconvenienced and facing potential harm, but even some auto industry figures oppose the design.

Wei Jianjun, chairman of Great Wall Motor, has publicly criticized flush door handles, saying their contribution to drag reduction is "negligible," and that they are "heavy, poorly sealed, noisy, and reliant on electrical power, posing a safety hazard."

Volkswagen CEO Thomas Schafer prefers traditional designs, stating that while flush handles look good, they are "terrible to operate." Volkswagen has also shifted its approach. While the ID. Every1 concept car earlier this year featured flush handles, both the ID. Cross and ID. Polo showcased at the recent Munich auto show used more conventional handles.

In early September, Chinese auto industry regulators announced they were considering banning retracting door handles in electric vehicles due to safety concerns.

BYD Seal 06 with semi-flush door handles: flush with the body, but with an indented area for pulling. Photo: EV Marketplace

BYD Seal 06 with semi-flush door handles: flush with the body, but with an indented area for pulling. Photo: EV Marketplace

This potential ban follows the Ministry of Industry and Information Technology's (MIIT) May initiative to revise the mandatory national standard "Safety Technical Requirements for Car Door Handles," addressing risks posed by flush handles. This move is seen as part of a broader effort to enhance auto safety.

Tesla is now reevaluating its emergency door release design. Design chief Franz von Holzhausen stated in a September 17 podcast that the company is exploring ways to combine manual and electronic mechanisms for easier and faster exits in "panic situations."

It's unclear whether Tesla aims to retrofit all models or only new ones, but combining both methods for existing models seems unlikely, according to CNN.

In China, an increasing number of new vehicles this year are adopting semi-flush door handles (partially flush, partially indented), such as the Wenjie M8, Chery Fengyun A9L, BYD Seal 06, GAC Aion UT, FAW Audi Q6L e-tron, and the upcoming Voyah Taishan. With the safety risks of fully flush handles and the potential for a ban, the semi-flush design seems to be gaining traction.

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