A Design That Sparked Debate
Tesla helped mainstream flush-style door handles by pairing their minimalist look with aerodynamic benefits, as the design sits more cleanly within the bodywork. Over time, however, issues with the design have surfaced, with the problem being linked to at least 15 deaths in crashes where doors could not be opened after impact, with some occupants reportedly trapped inside vehicles that later caught fire.
Now, a 2023 Tesla Model S owner has filed a class-action lawsuit against the EV maker, alleging that the vehicle’s exterior and interior door handles are defective. According to Car Complaints, the suit further claims that the company concealed the defects from customers.
Aside from the alleged safety risk, the plaintiff, Robert L. Hyde, argued that he suffered “economic injury,” claiming the door-handle design reduces the EV’s value even though he was never involved in an accident.
Finding the Way Out
As with most cases involving the flush-style door-handle issue, the lawsuit highlights that losing power could prevent the doors from being opened from the outside. It acknowledges that while the front doors can be easily opened in an emergency, the manual release for the rear doors is hidden beneath the carpet, which could cause passengers to panic and struggle to locate it.
The lawsuit represents owners of Model S EVs from the 2023 model year to the present. As for Hyde, he claims that Tesla has refused to replace his vehicle or refund his money, and also alleges that the automaker has declined to fix the purported defects.
Taking Tesla to Court
Hyde filed the class action lawsuit in the U.S. District Court for the Central District of California.
While the outcome of the case remains uncertain, the days of flush-style door handles may already be numbered. In China, a new safety standard will ban the use of such designs – along with the yoke steering wheels seen in Tesla EVs – starting January 1, 2027. Given that the country is the world’s largest car market, the rule could force automakers to allocate resources toward redesigns if they want to remain competitive there.
It is also worth noting that Tesla is ending production of the Model S and Model X to free up factory space for its humanoid robot project, Optimus.


