Tesla's Woes: Elon Musk Faces New Headache as Door Issues Plague the Brand

Tesla faces a major federal investigation over electronic door handles that may trap people inside vehicles during emergencies. The National Highway Traffic Safety Administration is demanding comprehensive records after receiving reports of children stuck in hot cars and passengers unable to escape during crashes when the electronic systems failed.

The probe centers on Tesla's flush-mounted, retractable door handles that can malfunction when the car's 12-volt battery dies or loses power. NHTSA has received 16 reports of exterior door handle failures in 2021 Model Y vehicles alone as of October 27. But the problem appears wider - the investigation covers Model 3 and Model Y cars from 2017 to 2022.

Here's where it gets serious: some incidents involved children trapped in overheating vehicles, forcing rescue teams to break windows to get them out. Other cases saw people unable to escape after crashes when the electronic door systems stopped working. Bloomberg's earlier reporting revealed injuries and deaths linked to people trapped in Teslas after collisions or power failures.

The timing matters for Tesla's business. The company already faces scrutiny over various safety issues, and this investigation could lead to costly recalls or design changes. Tesla's design chief Franz von Holzhausen has said the company will modify its door handle design, suggesting internal recognition of the problem.

Other automakers are taking notice. Rivian is reconsidering its flush door handle designs. Volkswagen CEO Thomas Schäfer recently said customers don't want electronic door handles at all, and the company won't adopt them. This shift could affect the broader electric vehicle market's design trends.

China is moving faster on regulations. The country's Ministry of Industry and Information Technology has drafted new vehicle safety standards requiring clearer, more accessible emergency door release mechanisms inside vehicles. Public comments on these rules close November 22.

Tesla has until December 10 to provide all requested records to NHTSA. The agency wants documentation on door opening systems, handles, latches, 12-volt batteries, and related software across multiple model years. If Tesla fails to comply fully and on time, it faces fines of $27,874 per day, up to a maximum of $139 million.

For investors and the auto industry, this investigation signals growing regulatory pressure on high-tech vehicle features that prioritize aesthetics over basic safety functions. Traditional mechanical backups for electronic systems may become standard requirements, potentially increasing costs but improving emergency safety across all electric vehicles.