Tesla's door defect could lead to tougher rules for the entire auto industry

Tesla's electronic door handles, which have been linked to several deaths, could lead to stricter safety regulations across the auto industry. The National Highway Traffic Safety Administration (NHTSA) published a notice stating that complaints about Tesla's mechanical door release do not warrant a defect investigation. Instead, the issue should be addressed through broader rulemaking that would "mandate a robust and obvious door egress system in all motor vehicles." If finalized, all new vehicles would be subject to the new requirements.

Tesla's door handles operate electronically and sit flush against the vehicle for improved aerodynamics. They have been linked to several incidents where people were trapped inside their vehicles. In multiple cases, Tesla passengers who survived the initial crash later sustained serious injuries or died after being trapped inside a burning vehicle. China banned electronic door handles for safety reasons earlier this year, and NHTSA has been investigating cases where Tesla's handles become inoperable due to low-voltage battery problems.

The notice was published after Silicon Valley engineer Kevin Clouse filed a petition requesting a defect investigation, alleging that "the emergency egress controls for the mechanical door release are not readily accessible and clearly identifiable." Clouse filed the petition after a crash where his 2022 Tesla Model 3 suffered a total loss of electrical power and caught fire. Unable to locate the mechanical door handle, he had to climb into the back seat and exit through a rear passenger window. NHTSA denied the petition but said broader rulemaking was warranted.

However, immediate changes are not expected. The rulemaking process typically takes two to five years, meaning new requirements likely won't emerge until 2030 or later. The auto industry has historically pushed back against rules that impose additional costs. Congress has also introduced legislation requiring manual door releases in new cars and means for first responders to access vehicles when power is lost.

Last year, Tesla said it would redesign its electronic door handles, though no timeline was given. Design chief Franz von Holzhausen told Bloomberg the company aims to make the handles more intuitive in "a panic situation." That is cold comfort for victims' families. Andrew McDevitt, representing families in two fatal Tesla cases, urged NHTSA to move swiftly through rulemaking to develop and implement new federal safety standards to protect future occupants.