Starting January 1, 2027, China will require all new vehicles under 3.5 tons to feature mechanical emergency door releases on both interior and exterior handles, effectively curbing Tesla-style electronic flush designs. The regulation aims to ensure occupants and first responders can open doors manually during power failures from crashes or fires. This move addresses growing safety concerns over electronic systems that have led to access issues in emergencies.
Chinese regulators, through draft rules from the Ministry of Industry and Information Technology, are set to enforce mechanical manual releases for door handles on vehicles weighing up to 3.5 tonnes. These must allow unlocking from both inside and outside even if electronic systems fail, targeting designs reliant on power or software like Tesla's flush, electronically actuated handles. The policy, effective January 1, 2027, will apply to new models sold in China, the world's largest auto market where new-energy vehicles account for over 35% of sales according to the China Association of Automobile Manufacturers.
Safety data underscores the urgency. A Bloomberg analysis linked 15 deaths to incidents where Tesla doors could not open after crashes or fires damaged electrical systems. In the U.S., the National Highway Traffic Safety Administration has fielded complaints about flush handles failing during power loss, including cases requiring first responders to break windows for rescue. The NHTSA recently launched a defect investigation into over 170,000 Tesla Model 3 sedans, citing concerns that manual interior releases may not be easily identifiable in emergencies. While Shanghai-built Teslas include clear markings on these latches, vehicles from other factories do not.
Tesla faces significant redesign challenges, as all its models use electronic flush handles. Design chief Franz von Holzhausen has confirmed the company is developing a new handle integrating electronic and mechanical releases. Domestic rivals like BYD, Nio, Xpeng, and Li Auto, which also favor pop-out designs in premium trims, will need hybrid solutions to maintain aerodynamics while adding accessible mechanical overrides. Globally, Europe's UNECE Regulation No. 11 already emphasizes manual interior escapes, but China's focus on exterior releases could influence standards worldwide.
Owners of existing vehicles should familiarize themselves with manual release locations, as advised by fire and rescue organizations. Suppliers such as Huf, Brose, and Magna are expected to adapt door modules with redundant mechanical pathways, prioritizing fail-safe access over aesthetics.
