The hidden dangers of hidden door handles

Following reports of passengers and drivers being unable to open their doors after a crash, regulators in various countries have decided to revise or introduce new rules and requirements for the design and operation of car door handles. The main concerns relate to the use of flush door handles on the exterior of the car and electrical push button releases inside. Both types are often connected to an e-latch (electrically controlled door latch) that relies on an electrical command to operate. The central question is how the door can be opened if the battery is flat or the car has been damaged in a crash.

This question has often been answered by the vehicle manufacturer and in most cases, there is an emergency mechanical cable override, designed to allow the door to open. However, to maintain the high-tech vision, this emergency release is commonly concealed behind a piece of trim or, in some cases, connected to a hidden handle or out-of-sight lever.  

Obviously it is hoped that the emergency release is never needed, and although details of where it is and how to use it are all laid out in the Owners Handbook, it is not intuitive or easy for people to find or understand… especially in a panic situation or  moment of danger. 

From an OEM perspective it is clear that the safety of occupants, pedestrians and other road users must always be the prime consideration. However, security of the vehicle should not be forgotten, as the safety implications surrounding stolen vehicles being driven recklessly through urban areas can also lead to tragedy, this has been highlighted recently in the US with the "Kia Boyz" Tik Tok craze. 

With new requirements being considered (see below) and likely to be brought into force very soon, it would be easy for OEMs to panic and sacrifice Anti-Theft entirely for convenient, simple to open doors. SBD believe that it is possible to design safe and secure door systems that will meet both sets of regulations and local market needs. 

SBD Automotive's specialists have decades of experience in helping designers meet internal Anti-Theft targets so that products remain competitive and meet their customer needs. This always has to be achieved without compromising safety, assembly and production restrictions, and budgetary requirements.    

Potential regulation changes  

MIIT (China) 

In China, The Ministry of Industry and Information Technology have issued a draft for a new standard called Safety Technical Requirements for Automobile Door Handles. They also state that its release will also trigger amendments to three other regulations, including Occupant Protection in Frontal Collisions of Automobiles.  

From a visual design perspective, these regulations go as far as to ban fully concealed emergency releases and door handles  

(Reference)

NHTSA (USA) 

In the US, Tesla has been facing some user criticism over its Model Y door handle design. Complaints have included the obvious safety concerns but also about children being trapped in vehicles when the battery power is low and emergency services having to smash windows to get them out.  

The culmination of these various complaints has sparked an official investigation in September 2025 by the National Highway Traffic Safety Administration (NHTSA). To their credit it appears that Tesla have decided to carry out a design study. It’s believed that they are planning to use a conventional internal door handle that operates the latch either electronically or manually. It is also rumoured that they are looking to offer a replacement option for all affected vehicles.  

Although the NHTSA investigation is still on-going, it is reported that they are still collecting information from the public and records from Tesla, and it is likely that this will lead to some form of change to current safety regulations.   (Reference)

UN (Europe) 

Regulatory authorities in Europe are also looking into this issue following information received from the German technical experts (KBA). It is believed that they are exploring solutions that would allow the door mechanisms to remain operational even if power is lost. 

The KBA states: 

“The goal of these examples is to highlight the fact that in case of an accident, it could become tricky to open the doors from the inside of the vehicle, as from the outside of the vehicle without having read the manual beforehand.  

Therefore, our aim is to develop a proposal within the framework of UN Regulation No. 11 or other relevant regulations that enables doors to be opened intuitively in both electric and ICE vehicles, thereby helping to save lives”. 

(Reference)

"Safety should always be upper most in your mind when designing or specifying a locking system. But it should never be forgotten that Anti-Theft is a key part of any vehicle's overall safety. "

Sam Nelstrop APAC Consulting Manager SBD Automotive

To explore how upcoming door access rules could affect your security roadmap, schedule a complimentary discovery call with one of SBD Automotive’s Anti-Theft specialists.

And to deepen your understanding of secure access technology, download SBD Automotive’s Digital Key Guide. It explains the newest digital key standards, evaluates OEM and supplier approaches, reviews security models, outlines future service opportunities and provides clear guidance to support planning and partner selection.

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