China moves to Regulate Flush Door Handles in Electric Vehicles
Governments worldwide are pushing for increased vehicle efficiency thru stricter emission regulations, leading automakers to prioritize aerodynamic improvements. Flush-mounted, or ”hidden,” door handles have gained popularity for their sleek aesthetics and potential aerodynamic benefits, though their practicality has been questioned. Now, China, the world’s largest car market, is proposing regulations that could effectively end their use within a year unless they meet stringent safety requirements.
Manufacturers have claimed that these hidden handles can improve a vehicle’s aerodynamic coefficient by up to 0.03 CD. However, independent investigations suggest a more modest improvement of around 0.005 Cd. This translates to an energy saving of approximately 0.6 kWh per 100 km, a small amount in the short term, but perhaps notable over the lifespan of a vehicle. despite this potential, the mechanical systems required for flush handles add weight – up to 8 kilograms in certain specific cases – offsetting some of the aerodynamic gains.
Concerns are growing regarding the safety of these handles, particularly in emergency situations. studies indicate that mechanical shooters currently account for 12% of repairs in electric cars. the Automotive insurance Security Index of China (C-IASI) revealed that in lateral impact tests, cars with electronic flush handles successfully opened in only 67% of cases, compared to 98% of vehicles with traditional handles.
Recent incidents in China have highlighted these safety risks. During a cold wave in Changchun in 2024, occupants were trapped inside an electric vehicle when the handles froze. Later that year, heavy rains in Guangdong caused short circuits in several electric cars, preventing door operation and forcing passengers to break windows to escape.
In response, chinese regulators are considering a ban on flush door handles unless they are equipped with a redundant mechanical system – a physical handle allowing manual door opening from inside the vehicle. This amendment mirrors regulations already in place in Europe. According to Chinese sources, a draft outlining these demands and exceptions is expected to be finalized this month, with manufacturers given at least one year to comply by either installing conventional handles or implementing these redundant systems.
