China Pulls the Plug on Electronic Door Handles Following Fatal EV Fires
After a string of fatal battery fires left passengers trapped behind unresponsive electronics, China is pulling the plug on the hidden door handle trend. The Ministry of Industry and Information Technology (MIIT) has finalized new safety standards that ban purely electronic door handles on electric vehicles, forcing a return to mechanical releases for both the interior and exterior of the car. These regulations take effect on January 1, 2027, signaling a massive retreat from the "minimalist" design philosophy that has dominated the EV sector for a decade.
This regulatory hammer hits the "hidden" flush-mounted handles popularized by Tesla and copied by almost every major player, from Xiaomi and Kia to nascent EV startups. While these designs helped shave points off drag coefficients and provided a high-tech silhouette, they have become a liability. In multiple high-profile accidents, rescuers were forced to smash windows or use pry bars to reach occupants because the vehicle’s power failed, leaving the handles retracted and the latches dead.
12V Vulnerabilities Drive Regulatory Action
The move follows intense public outcry over crashes involving the Xiaomi SU7 and various premium EVs. In high-stress crash scenarios, electric vehicles face a unique power paradox: the vehicle’s safety systems are designed to instantly trigger a "pyrofuse," disconnecting the high-voltage battery to prevent electrocution or further fire. This shift places the entire burden of door operation on the 12V lead-acid or lithium-ion auxiliary battery.
If that 12V system is crushed or disconnected during the impact—a common occurrence in front-end collisions—the electronic actuators that pop the handles or release the latches become useless bricks. Passengers and first responders then find themselves fighting against a car that is physically sealed shut. The new legislation mandates that every door must feature a dedicated mechanical linkage. This ensures that even with zero volts remaining in the system, the door can be opened with a physical pull.
Technical Specifications and the 2029 "Grace Period"
The MIIT's roadmap gives manufacturers a tight window to overhaul their assembly lines. While the mandate applies to all new models hitting the market on January 1, 2027, vehicles already approved for sale have until January 1, 2029, to implement the redesign.
The law goes beyond just requiring a physical cable; it dictates ergonomics. For "semi-hidden" designs—where the handle is flush but includes a cutout—the rules specify a minimum recessed space of 60mm by 20mm (approximately 2.4 inches by 0.8 inches). This ensures a gloved hand or a person in a state of panic can gain a firm grip. Furthermore, manufacturers must now install high-contrast internal signage or lighting to mark the location of manual overrides, moving away from the "hidden-in-plain-sight" aesthetic that often confuses passengers during emergencies.
A Logistical Nightmare for "Button-Free" Startups
Perhaps most telling is the carve-out for gas-guzzlers. Internal combustion engine (ICE) vehicles remain exempt from this specific mandate for now, despite many luxury models adopting flush handles. This distinction underscores the Chinese government's urgency regarding the rapid extraction window required during EV-specific thermal runaway events.
This shift is a logistical nightmare for startups that have banked their entire brand identity on a button-free, flush aesthetic. Companies like Tesla, which is reportedly already testing mechanical revisions for its next-generation platform, must now decide whether to maintain two separate production lines or standardize a "China-compliant" mechanical handle globally.
As the dominant force in the EV supply chain, China’s move essentially sets the new global baseline. With European safety agencies already expressing similar concerns over electronic entry, the industry's next great engineering challenge isn't just range—it’s figuring out how to maintain a slippery 0.20 drag coefficient while re-introducing the physical levers of the past.