NHTSA to mandate manual overrides for electric vehicle door handles

The U.S. National Highway Traffic Safety Administration (NHTSA) announced a rulemaking process to create a federal safety standard that requires a "robust and obvious" door egress system in all new vehicles. The initiative follows a petition concerning the 2022 Tesla Model 3’s emergency mechanical door release, which was denied due to insufficient complaint data, and a series of fatal crashes where flush, electronically‑operated door handles prevented occupants or rescuers from opening doors after power loss. Bloomberg reports at least 15 deaths linked to such incidents, many involving post‑collision fires.

The forthcoming rule will apply to every automaker, not only Tesla, and will obligate manufacturers to provide a manual override for flush door handles. Tesla and Rivian have already signaled redesigns of their door‑handle systems, and internal safety concerns raised within Tesla were reportedly overridden by CEO Elon Musk. The regulation aims to eliminate the current gap in Federal Motor Vehicle Safety Standard 206, which does not specify labeling or positioning for manual releases.

The rulemaking signals a broader regulatory focus on occupant safety in electric vehicles and will shape design standards across the U.S. auto industry.