Federal regulators in the United States have expanded an investigation into potential safety defects with the Tesla’s flush-mounted, electronic door handles. The National Highway Traffic Safety Administration (NHTSA) has confirmed a surge in complaints from Model Y owners who reported being trapped inside their vehicles after a battery failure — in some cases involving young children, following the announcement of the initial probe.
At the same time, the company is facing a new lawsuit in Wisconsin over the same concerns.
Investigation Expands After New Reports
The NHTSA’s Office of Defects Investigation first opened the probe in mid-September following nine complaints related to inoperative exterior door handles on 2021 Model Y vehicles. Within ten days, that number had nearly doubled. In its October 27 letter to Tesla, the agency noted that “16 reports” were received about door handles failing to operate due to a low-voltage 12V battery.
Several of these reports involved children trapped inside hot vehicles, prompting emergency responders to break windows to free occupants. One Santa Barbara, California owner said their eight-month-old infant was “flushed, diaphoretic, and crying” after being trapped for nearly 30 minutes in a car that reached 104°F (40°C) internally.
The NHTSA has ordered Tesla to provide detailed records by December 10 regarding design, software, and component failures related to its electronic door mechanisms.
Legal Action Adds Pressure
The regulatory pressure coincides with a wrongful death lawsuit filed in Wisconsin state court over a fatal Model S crash that occurred last November. The suit alleges that five occupants were killed when they became trapped inside the burning vehicle after its electronic doors failed to open. The complaint accuses Tesla of negligence, claiming the company was aware of “foreseeable risks” linked to its flush door handles and post-collision fire hazards but failed to take corrective measures. (via Automotive News)
Attorneys for the victims’ families argue that Tesla “disregarded basic crashworthiness principles” by designing vehicles that rely on electronic systems vulnerable to power failure during a fire or crash.
Although Tesla vehicles include mechanical door-release mechanisms, many owners and passengers are unaware of their locations or how to use them in emergencies, the suit alleges.
Tesla’s Reaction
Following reports of the incidents, Tesla’s chief designer Franz von Holzhausen confirmed the company is working on modifications to improve door operability “in panic situations.” Other automakers are now reevaluating similar designs — Volkswagen has stated it will avoid flush-mounted handles altogether, while China’s auto safety regulator is drafting new standards requiring clearer and more accessible manual releases.
Tesla has not publicly commented on the latest NHTSA probe or the Wisconsin lawsuit. If the automaker fails to meet the December deadline, it could face fines of up to US$27,874 per violation per day, with a potential maximum penalty exceeding US$139 million.
