Tesla Hit With Legal Scrutiny Over Door Handle Safety Issues

Tesla faces mounting legal and regulatory scrutiny over the design of its electronic door handles, following a fatal 2024 crash in Wisconsin and a widening federal investigation.

A lawsuit filed by the families of Jeffrey and Michelle Bauer alleges that the 2016 Model S they were riding in failed to provide operable door handles after a crash, resulting in the deaths of all five occupants. According to the Dane County Sheriff’s Office, the vehicle, driven by Barry Sievers, veered off a semi-rural road in Verona, Wisconsin, and struck a tree. A nearby resident reported that the car caught fire and that she heard screams for up to five minutes after calling 911.

The lawsuit accuses Tesla of negligence in the design of both the door handles and battery pack, claiming that these features could have made the crash more survivable. Tesla vehicles use electronic door releases that trigger mechanical operations only under certain conditions. While the 2016 Model S had a mechanical fallback for the front doors, the rear doors required access to a hidden release under the carpet—information included in the owner’s manual but unlikely to be known to most passengers.

“Tesla had heard repeated complaints about its door handles and did not modify its design to something simpler or more robust in a crash,” the lawsuit states. It cites Tesla design chief Franz von Holzhausen, who in 2025 said the company was developing a combined electronic-mechanical release button. The suit also notes that later Tesla models include clearer labels for emergency door releases, suggesting that earlier designs lacked visibility.

The complaint further claims that the 2016 Model S lacked fire safety materials introduced in newer models, such as intumescent compounds that expand under heat to slow fire spread. It alleges these omissions failed to meet voluntary UL and SAE battery safety guidelines. Plaintiffs are seeking unspecified compensatory and punitive damages against Tesla, as well as claims against the driver and his insurer.

Separately, the National Highway Traffic Safety Administration (NHTSA) has expanded its investigation into Tesla’s flush-mounted, retractable door handles, requesting records related to Model Y vehicles from 2021 and Model 3 and Model Y units from 2017–2022. The review covers door operation, latch systems, 12V batteries, and related software.

“Owners reported being unable to enter or exit their cars due to battery power loss or other malfunctions impeding door handle use,” NHTSA said. As of Oct. 27, 2025, the agency had received 16 reports involving Model Y vehicles where door handles became inoperative due to low battery voltage. In some cases, first responders had to break windows to free trapped occupants.

Meanwhile, other automakers—including Rivian and Volkswagen—are reconsidering flush-mounted handle designs. Volkswagen CEO Thomas Schäfer said customers have rejected electronic flush handles and that VW has no plans to adopt them.

In China, regulators are drafting new vehicle safety standards requiring clearly marked and more accessible emergency door releases. Public comments on the proposal remain open through Nov. 22, 2025.

NHTSA has given Tesla until Dec. 10 to submit the requested documents. Failure to comply could result in fines of up to US$27,874 per violation per day, with a maximum penalty of US$139.4 million, the agency warned.