China's New Law Requires Manual Door Handles in All Passenger Cars

In recent years, a prominent design trend in electric vehicles has been the adoption of "hidden" or "flush" door handles. These handles rest flat against the car's surface, enhancing its sleek appearance and improving aerodynamics. However, this innovative design has led to significant safety concerns. In the event of a collision that causes a loss of power, these electronic handles may fail to deploy, potentially trapping occupants inside the vehicle.

In response to these safety issues, the Chinese government has implemented new regulations through law GB 48001-2026, mandating that all new passenger vehicles include a manual method for opening doors. This means that, regardless of electronic malfunctions or battery failures, individuals can manually operate the handle to exit the vehicle. This regulation will take effect on January 1, 2027, and is poised to alter the manufacturing processes for virtually every electric vehicle in the market.

The stipulations in the law are incredibly detailed regarding the structural requirements for these manual handles. It's not sufficient to merely include a hidden backup cable; the mechanical components must endure considerable force: the handle itself must resist up to 500 Newtons—equivalent to supporting a weight of approximately 112 pounds—without compromising its integrity.

Manufacturers are also required to ensure adequate space for a person's hand to access the handle in emergency scenarios. The external handles must be designed with a minimum width of 2.36 inches and a height of 0.79 inches, allowing rescuers wearing heavy gloves to grasp and pull the door open effectively.

Inside the vehicle, the regulations are equally strict. Passengers will no longer face difficulties locating exit buttons, as every side door must feature at least one independent manual handle that is easily visible and located within 11.8 inches of the door's edge.

To further aid in emergency scenarios, car manufacturers must also install clear signage detailing the operation of the handles. These signs must measure at least 3.94 inches by 2.76 inches and provide instructions either in Chinese or through universally understandable illustrations. The text must be sufficiently large, with letters at least 0.24 inches tall, to remain legible under duress.

This new standard is particularly significant for manufacturers such as Tesla, Nio, and Xiaomi. Currently, approximately 60% of popular vehicles in China utilize hidden handles. Models like the Tesla Model 3 and the Xiaomi SU7 may require redesigns to comply with these new regulations. While Tesla's handles do not use electronic pop-up mechanisms—they remain mechanical—some vehicles contain emergency cables that are not easily accessible.

The transition to these new standards will occur in phases. Any manufacturer seeking approval for new car models must adhere to the majority of these regulations starting July 1, 2026. By the summer of 2027, all vehicles sold must comply fully, providing engineers with limited time to adapt their designs.

While this regulation may initially seem localized to China, it's important to note that China is the world's largest electric vehicle market. Consequently, when such a mandate is established, manufacturers often modify their designs globally to reduce costs. Therefore, a decrease in "disappearing" handles in the U.S. and Europe may soon follow.

Ultimately, this initiative signifies a triumph for practical safety measures. While technology enhances vehicle features, it should never complicate the process of evacuating a car during emergencies. By integrating reliable manual door handles, the auto industry is ensuring that advancements in design do not compromise occupant safety.

Via