China recalls more than 4 million Teslas over hidden door-handle system safety concerns

Minimalist, flush-fitting door handles have become a defining feature of modern electric vehicles (EVs), but the increasingly popular design is now facing major safety scrutiny in China. More than 4 million vehicles are being recalled over concerns that hidden door handles can be difficult to locate or operate during emergencies. The recall includes 2.98 million Chinese-made Tesla vehicles, making it one of the largest vehicle recalls in China.

Other manufacturers affected include Chinese EV makers XPeng, Xiaomi and Geely. As part of the recall, affected vehicles will receive warning labels on the interior doors and a software update designed to automatically lower the windows following a crash. The measures are intended to make it easier for occupants and rescuers to escape if the vehicle's electrical systems fail. The safety concerns intensified following two fatal crashes involving Xiaomi EVs in China, where power failures were suspected of preventing the vehicles' doors from being opened.

Tesla said it was recalling certain Model 3, Model Y, Model S and Model X vehicles because their door handles can be difficult to identify and operate. Tesla said in a statement on Friday that it was recalling some of its Model 3, Y, S and X vehicles due to door handles that are "difficult to identify and operate because their colour is similar to the interior trim".

The company added, "In extreme situations such as a severe collision causing the vehicle's low-voltage system to fail, this could hinder occupants from quickly opening the doors to escape and impede rescue efforts by those outside the vehicle, posing a safety hazard," it said. Tesla plans to add warning labels to affected vehicles and deploy a software update that will automatically lower the windows after a collision. It remains unclear whether Tesla and the other affected manufacturers will introduce similar recalls or safety measures for vehicles sold outside China.

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Why are hidden door handles under scrutiny?

Flush and concealed door handles became increasingly popular among EV manufacturers because they contribute to a sleek, aerodynamic appearance. Tesla's Model S, launched with its distinctive retractable handles, helped establish the design as a signature feature of modern electric cars. Tu Le, founder of consultancy Sino Auto Insights, said the design ‘snowballed’ after Chinese manufacturers began copying the "sleek" appearance of Tesla's Model S sedan from 2014 onwards. However, Le believes the current recall measures may not provide a permanent answer to the safety concerns. He described the use of warning labels and a software update as more of a "band-aid" than a lasting solution.

China to restrict hidden door handles

Chinese authorities announced restrictions on hidden door handles in February. Under rules scheduled to take effect on 1 January 2027, new vehicles sold in China will be required to have a mechanical door release on both the inside and outside of the vehicle. The move reflects growing concerns that electronically operated or concealed handles could become difficult or impossible to use following a serious crash or electrical failure.

Tesla's door-handle technology has also attracted attention from US safety regulators. The company previously faced a probe by the US National Highway Traffic Safety Administration (NHTSA) after reports that door handles stopped functioning and left children trapped inside vehicles. In July, NHTSA proposed developing a new formal safety standard covering door-handle safety across the automotive industry. The developments in China could therefore signal a broader shift away from fully concealed electronic door handles, as regulators increasingly prioritise emergency access and occupant safety over minimalist vehicle design.