Tesla’s electric door and flush-handle systems are raising safety concerns after several crashes in which occupants and rescuers could not exit or access vehicles when power failed, according to Bloomberg. The technology trade-off threatens both user safety and regulatory scrutiny.

Sleek Design, Hidden Risks

Tesla’s flush exterior handles and electrically actuated door systems were designed for aerodynamic efficiency and a minimalist look. The Model S, introduced in 2012, featured flat surfaces that improved range and reduced wind noise. But this left little room for mechanical parts, leading Tesla engineers to use wire-release mechanisms hidden in the interior for emergencies.

Manual releases vary by model. In many Model Y vehicles, rear-door cables are located under carpet or trim, requiring removal of panels to access—a nearly impossible task during a fire or high-stress crash scenario. The Cybertruck took this further, eliminating external handles altogether in favor of buttons inside the cabin.

Safety Incidents Raise Alarm

A December 2023 crash in Virginia highlighted the risks. Off-duty firefighter Max Walsh arrived at the scene of a Tesla Model Y fire. Unable to open the electrically powered doors, he smashed a window to rescue the driver. But the passenger, pinned by airbags and trapped by inoperable doors, suffered severe burns and lasting lung damage before rescuers with hydraulic cutters arrived.

Other cases have been equally tragic. In November 2024, a Tesla Cybertruck in California crashed and caught fire, killing three students who were trapped inside. The same month, a Model S fire in Wisconsin left five dead, with investigators suggesting escape was hindered by locked or nonfunctional doors.

Regulators Begin to Respond

Authorities are starting to pay attention. In China, regulators are considering a ban on fully concealed door handles by 2027. Europe has taken incremental steps to improve post-crash rescue protocols. In the U.S., the National Highway Traffic Safety Administration (NHTSA) has acknowledged awareness of complaints but has not mandated design changes.

Safety advocates warn that crash tests currently measure survivability on impact, but not whether occupants can escape afterward. That gap leaves automakers free to prioritize aesthetics and aerodynamics over evacuation safety.

Impact on EV Industry

Tesla has built its brand and trillion-dollar valuation on sleek design and technological leadership. Yet hidden manual releases and reliance on power-dependent systems may erode consumer trust. Owners often remain unaware of where emergency releases are located or how to operate them under duress.

Competitors emphasizing intuitive, physical fail-safes may gain an edge if Tesla resists change. Insurers, regulators, and consumers are increasingly questioning whether design should ever come at the cost of life-saving usability.

What Owners and First Responders Should Know

Manual release locations differ by model. For example, in the Model S, front-door releases are next to the window switch; rear releases are hidden beneath the carpet under the back seats. Owner manuals contain instructions, but renters, passengers, or new drivers may not know them in time. First responders must familiarize themselves with Tesla models to expedite rescue, as every second counts when dealing with lithium-ion battery fires.

EVXL’s Take

Tesla’s doors embody a tension between futuristic design and real-world safety. When electrical systems fail, sleek flush handles can become deadly traps. Regulators are beginning to question whether the industry has gone too far in prioritizing form over function.

The bigger question: Will Tesla proactively redesign its doors to lead on safety, or will governments force the change? For now, the burden falls on owners and rescuers to know the hidden workarounds.

What do you think—should regulators mandate visible, mechanical fail-safe handles on all EVs? Share your thoughts in the comments.