US EV Door Safety Rulemaking

Following a December 2025 high‑speed crash in San Jose that trapped a driver and infant, NHTSA moved to address the broader safety issue of electronic door handles. On July 23 2026 the agency announced formal rulemaking to create a federal standard requiring a “robust and obvious” emergency door‑egress system on all new vehicles. The move was prompted by a series of fatal crashes—at least 15 deaths—where flush, electronically‑operated handles on Tesla Model 3 and Model Y cars prevented occupants or rescuers from opening doors after power loss.

A petition for a defect investigation into the concealed mechanical release on 2022 Model 3s was denied, with NHTSA noting only a single matching consumer complaint and that FMVSS 206 does not cover labeling or placement of manual releases. The forthcoming rule will obligate every automaker to provide a clearly visible manual override, closing the gap in the existing standard.

Congressional legislation such as the SAFE Exit Act and parallel efforts in Europe and China are reinforcing the regulatory focus. Automakers—including Tesla, Rivian, and others—have pledged redesigns of door‑handle systems, and internal safety concerns at Tesla reportedly were overridden by senior leadership. NHTSA will gather data, hold stakeholder outreach, and open a public comment period before issuing draft standards, with compliance expected in the early 2030s.