China has initiated its largest car recall to date, affecting more than 4 million electric vehicles equipped with minimalist retractable door handles. The recall includes 2.98 million Chinese-made Teslas, along with vehicles produced by Chinese manufacturers XPeng, Xiaomi, and Geely. Authorities raised safety concerns that these hidden handles, which typically tuck into the door panel and extend as a driver approaches, are difficult to locate and operate during emergencies.
The safety of hidden door handles came under scrutiny following two fatal crashes in China involving Xiaomi electric vehicles. In those instances, investigators suspected that power failures prevented the doors from being opened. Tesla's door designs have also been the subject of an investigation by U.S. safety regulators following reports of malfunctions that allegedly left children trapped inside vehicles.
Tesla issued a statement on Friday regarding the recall of certain Model 3, Y, S, and X vehicles. The company noted that the handles can be difficult to identify because their color matches the interior trim, potentially hindering occupants or rescuers after a severe collision that causes low-voltage system failure. To address the issue, Tesla stated it will apply warning labels to the affected vehicles and deploy a software update designed to automatically lower windows following a collision.
The regulatory response in China sets a significant precedent for the global automotive industry. In February, Chinese authorities announced a ban on hidden door handles that lack a mechanical override. By January 1, 2027, all cars sold in China must be equipped with mechanical releases on both the interior and exterior of the doors. This change will require manufacturers to alter their signature "minimalist" designs to meet the new hardware requirements, potentially ending the trend of fully retractable handles in the world's largest auto market.
The impact may extend beyond China as international regulators consider similar measures. In July, the U.S. National Highway Traffic Safety Administration (NHTSA) suggested creating a new formal safety standard for all carmakers regarding door electronic systems. While it is not yet known if Tesla, XPeng, Xiaomi, or Geely will expand these recalls to other global markets, the Chinese deadline of January 2027 provides a clear timeline for when the physical design of new electric vehicles must change. The BBC has contacted these companies and the NHTSA for further comment on global implications.