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Recent media reports on February 2 revealed that China has officially banned the use of hidden (flush) door handles in electric vehicles, becoming the first country to prohibit this design. The feature, widely popularized by Tesla$TSLA , has come under increasing global scrutiny following several safety concerns and accident investigations.
Critics argue that this design is less about innovation and more about prioritizing appearance over passenger safety. In one widely reported accident in Wisconsin, USA, a Tesla Model S collision allegedly left passengers trapped inside because the door handle system malfunctioned, preventing quick access during rescue efforts.
Data from the China Insurance Automotive Safety Index (C-IASI) further intensified the debate. Their tests suggested that hidden handles successfully deploy after a side collision around 67% of the time, compared to roughly 98% for traditional mechanical handles — a significant safety gap.
Industry figures have also spoken out. Wang Jianjun of Great Wall Motors stated that the aerodynamic benefits of flush handles are minimal, while they add weight, increase sealing difficulty, and can freeze in cold weather — making them impractical in real-world conditions.
China’s Ministry of Industry and Information Technology has now mandated that all vehicle doors must include a mechanical emergency release handle with a minimum operational space, ensuring doors can be opened manually during emergencies.
This regulation puts pressure on Tesla, whose domestic lineup relies heavily on hidden handles. Redesigning them would require new tooling, structural adjustments, and electrical modifications — potentially costing millions.
Other EV manufacturers are also reacting quickly. A large percentage of top-selling new-energy vehicles use similar handle designs, and brands are already shifting toward semi-hidden or traditional solutions to meet the 2027 compliance deadline.
The change isn’t as simple as replacing a handle. Door structures, safety validations, and crash testing must all be redone. Industry insiders warn that the cost and time required for compliance could be especially challenging for smaller automakers.
Vehicle owners in colder regions have long reported practical issues — such as handles freezing shut in winter — requiring improvised methods to open doors.
Ironically, hidden handles were originally introduced to reduce drag and slightly improve driving range. However, regulators now believe that any minor efficiency gain does not justify the potential safety trade-offs.
China’s move has already drawn global attention. European regulators are reviewing similar measures, and U.S. agencies continue investigating related incidents. Tesla also faces ongoing legal challenges tied to safety complaints.
In the end, this debate highlights a broader industry lesson: even small design elements can become life-critical in emergencies. China’s intervention signals a shift toward prioritizing practical safety over purely aesthetic innovation