China may soon ban fully retractable and flush car door handles, a design feature that has become a hallmark of many electric vehicles (EVs), including all of Tesla’s vehicles, in recent years. While the sleek, flush handles are often praised for their styling and more importantly, their aerodynamic benefits, regulators argue the risks now far outweigh the advantages.
New Regulations on the Horizon
According to industry insiders, Chinese authorities are close to finalizing mandatory safety standards that would prohibit fully hidden door handles. A draft proposal is expected this month, with enforcement anticipated beginning in July 2027 after a one-year transition period.
Automakers will still be allowed to use semi-retractable or conventional handles, but all future designs must include a mechanical backup system to function during a power failure. (via Weixin)
The Safety Issues Behind the Ban
Although automakers have touted aerodynamic improvements of up to 0.03 Cd from flush handles, independent research shows the real gain is closer to 0.005 Cd—equating to just 0.6 kWh of energy saved per 100 km, a nearly negligible figure. Adding to it, the electric motors and mechanisms add up to 8 kg of weight, often cancelling out any marginal efficiency.
Reliability is another major issue. Reports indicate electronic handles cost roughly three times more than mechanical ones, yet fail eight times as often. One major EV brand saw door handle failures account for 12% of all repair cases.
But it is safety that has pushed regulators to act. In crash testing by the China Insurance Automotive Safety Index, vehicles with hidden electronic handles had just a 67% success rate in doors opening after a side collision, compared to 98% for traditional handles. Real-world cases have been even more alarming. In 2024, subzero temperatures in Changchun froze handle motors, trapping occupants inside. That same year, heavy rains in Guangdong caused electrical short circuits, forcing passengers to break windows to escape.
Rising Complaints and Accidents
China’s National Accident In-Depth Investigation System reported a 47% increase in accidents caused by door handle failures in 2024, with hidden designs responsible for more than 80% of cases. Consumer complaints also surged, particularly involving children. The China Consumers Association noted a 132% spike in reports of children’s fingers being pinched by automated handles, sometimes causing fractures.
Industry Pushback
Not all automakers embraced the flush-handle trend. Great Wall Motor’s chairman Wei Jianjun has long criticized the feature, calling it heavy, costly, and dangerous. Others, like Volkswagen and FAW-Audi, have opted for semi-hidden handles with built-in mechanical failsafes, such as deployable pull cords for emergency rescues.
The impending ban is part of a broader global conversation about vehicle safety and design. Regulators in Europe, for example, plan to strip five-star ratings from cars that bury essential functions—like wipers or hazard lights—inside touchscreen menus.
