NHTSA to draft new federal door-safety rules after Tesla deaths reveal egress risks

U.S. auto-safety regulators will begin drafting a new federal rule requiring all new vehicles to have a “robust and obvious” system for exiting when power is lost, the National Highway Traffic Safety Administration announced July 23. The move follows a series of incidents—including multiple Tesla crashes—in which occupants or rescuers could not open doors after a vehicle lost power or caught fire. NHTSA said it would evaluate potential requirements during a formal rulemaking process, which could take years to finalize and impose new Federal Motor Vehicle Safety Standards. The decision grants a petition filed in November 2025 by a Silicon Valley engineer who argued that electronic and “hidden” door-latching systems—common on EVs—create a “critical, life-threatening safety gap.” Bloomberg News reported at least 15 deaths across a dozen incidents in which people were trapped inside Tesla vehicles after crashes and subsequent fires. Tesla’s use of flush, electrically operated door handles has been a focus of scrutiny; internal emails cited by Bloomberg showed CEO Elon Musk insisted on the design despite internal safety concerns. NHTSA also denied a separate petition requesting a safety-defect investigation into Tesla Model Y vehicles after complaints about children being trapped. Meanwhile, Rep. Robin Kelly (D-Ill.) introduced the SAFE Exit Act in January 2026, which would mandate manual door releases, clear labeling, and improved first-responder access in all new cars. Industry analysts warn that even with swift rulemaking, a final compliance deadline for automakers is unlikely before 2030. NHTSA did not provide additional details in its filing and did not immediately respond to requests for comment. Tesla also declined to comment.