U.S. Investigates 179,000 Teslas After Futuristic Door Design Raises Safety Concerns

In the shadow of a fiery Cybertruck wreck in Piedmont, California, two young survivors gasped for air, trapped by doors that refused to yield. This November 2024 tragedy underscores a decade-long pattern: Tesla’s electronic door systems, championed by CEO Elon Musk in 2016 despite engineer warnings, have contributed to at least 15 fatalities across the U.S., as crashes ignite and power fails.​

Musk overrode safety concerns about power-dependent doors that could trap occupants in emergencies, prioritizing his vision of sleek, minimalist design. The choice shaped the Model 3, Model Y, and Cybertruck—now millions of vehicles on roads worldwide. Engineers had flagged risks of doors becoming inoperable without electricity, but the electronic latches prevailed.​

Fatal Crashes Expose Vulnerabilities

Bloomberg’s probe documented 15 deaths over 10 years where post-crash fires met locked electronic doors. More than half occurred since November 2024, amid Tesla’s expanding fleet. Over 140 complaints have reached federal regulators, highlighting failures in the 12-volt battery that powers latches, windows, and controls.​

When crashes damage or deplete this battery, doors lock from inside and out. Manual backups exist but hide behind unmarked trim panels, demanding precise, multi-step actions amid smoke and panic—steps most cannot perform.​

Tragedies in Piedmont and Toronto

In Piedmont on November 27, 2024, a Cybertruck carrying college students slammed into a tree and burst into flames. Krysta Tsukahara, 19, and Jack Nelson, 20, endured the impact unscathed but succumbed to smoke inhalation, unable to escape. Autopsies confirmed no fatal crash injuries. A fourth passenger fled after a friend smashed a window from outside.​

Weeks earlier in Toronto, a Model Y veered into a guardrail, erupted, and claimed four lives. Bystander Rick Harper shattered a window to pull one woman free, but the others remained trapped. Harper later described her desperate struggle and the doors’ refusal to open.​

Survivors’ Harrowing Escapes

Kevin Clouse faced his own inferno in a 2023 Georgia Model 3 crash. After a head-on collision, he searched vainly for the hidden manual release, then crawled to the back seat and kicked out a window. He survived with grave wounds needing three surgeries, including hip replacement, later testifying to the terror of a sealed, burning cabin.​

Such accounts reveal a pattern: Tesla’s design leaves occupants reliant on obscure mechanisms. Front releases are tiny levers near switches; rear ones lurk under removable panels, demanding cover removal and cable pulls. Some Model Ys lack rear releases entirely.​

Regulatory Scrutiny Intensifies

The National Highway Traffic Safety Administration launched probes into over 353,000 vehicles. A September 2025 inquiry targets Model Y door failures; December’s examines Model 3 emergency releases. Complaints cite sudden 12-volt failures stranding owners.​

China’s regulators propose banning flush, electric-only handles by January 2027, mandating mechanical releases that function powerless, with visible access. Tesla sells about 480,000 units yearly there.​

Tesla’s Measured Response

Design chief Franz von Holzhausen revealed in September 2025 plans for hybrid electronic-manual releases, but offered no rollout date or retrofit details for existing fleets. The move followed Bloomberg’s reporting and NHTSA actions.​

Tesla’s new safety page asserts automatic unlocking in severe crashes, though caveats limit it by region, model, and build date—leaving ambiguity for current owners. In Texas lawsuits over burn injuries, the company claimed no duty to warn of defects, diverging from typical liability standards. Unlike Ford and Fisker, which recalled for similar flaws, Tesla has issued none.​

Owner Adaptations and Broader Data

Drivers now stock glass breakers and escape tools; online forums share tutorials for hidden releases. Consumer Reports petitions industry-wide fixes.​

Tesla logs 210 door complaints in a decade—outpacing 310 from all other automakers combined. Among 70 models with electronic systems, Tesla’s rate leads, amplified by the Model Y’s status as 2023-2024’s top seller.​

As NHTSA probes deepen, lawsuits proliferate, and global rules tighten, Tesla confronts demands for redesigns or recalls. With a $1.5 trillion market cap, it holds resources to protect millions of drivers, but action hinges on regulators, courts, or internal shifts—leaving lives in the balance.