Tesla is working on a new door-opening system that combines mechanical and electronic mechanisms

Javier Cantagalli     18 September 2025     3 min.
Tesla is working on a new door-opening system that combines mechanical and electronic mechanisms

Balancing technological innovation with practical safety, especially in emergency situations, is the goal that Tesla is pursuing with the new door-opening system for its vehicles that it is currently developing.

Tesla is developing a new door-opening system for its vehicles designed to make it easier for occupants to evacuate in emergency situations. This was announced by Franz von Holzhausen, the renowned chief designer of the American company, in statements to the media.

This initiative by Tesla follows some worrying reports in the media referring to the inability to open doors in dangerous situations.

Tesla Door Handle

The U.S. National Highway Traffic Safety Administration (NHTSA) recently opened a preliminary investigation into the door handles of the 2021 Tesla Model Y after receiving complaints from drivers who reported that the doors could not be opened from the outside, even in cases where children were trapped inside. The NHTSA said the problem could be related to a lack of power from the 12-volt battery, without drivers receiving any low-voltage warnings. Although the investigation focuses on the exterior handles, which do not have a manual backup system, problems with the internal opening mechanisms have also been reported.

If you own a Tesla, don’t forget to read the vehicle manual

Regarding the latter, we should remember that even if the vehicle loses power, Tesla has integrated mechanical handles on both the front and rear doors of its most modern models that allow occupants to exit the vehicle after an accident. The rear door handles, however, are hidden and difficult to access, especially if the rear-seat passengers have not been informed of their existence. In any case, after an accident, if passengers are somewhat dazed, they are quite likely not to remember that the handles exist and not know how to get out of the vehicle.

Von Holzhausen, Tesla’s chief designer, addressed this issue in a recent interview, stating that Tesla is working on combining the standard electronic door-opening button with a backup mechanical lever, which is activated in the event of a power loss.

“We currently have a new door-opening system that combines the electronic mechanism with the manual one. We want muscle memory to lead to the right action in a moment of panic. In this way, simply pulling the lever a bit further activates the manual mechanism. I think the idea of combining the electronic and manual opening mechanisms makes a lot of sense and is the way forward.”

Tesla Model Y Performance 2025 00003

Regulatory pressure on this issue, however, is not limited to the U.S. market. In China, authorities are considering banning flush electronic door handles without a mechanical backup. Von Holzhausen has stated that Tesla is studying these new regulations and working on an appropriate solution to comply with the requirements set by the authorities.


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