AUTONEWS

Why are flush-mounted car door handles becoming increasingly common?

Getting into a car increasingly involves pulling a flush-mounted handle that pops out automatically. This invention isn't new; cars on the market have featured this solution for years. You might be one of those people who view it as an interesting aesthetic detail that gives the car a more modern look. But the truth is, in most cases, this system isn't installed simply to make the car look more modern.

The reason lies in the air, which acts as an invisible barrier the car must constantly cut through. The fewer protrusions on the car's surface, the less effort the engine requires and the less energy or fuel it consumes. Traditional door handles stick out several centimeters from the bodywork, disrupting airflow. But just how much does this aerodynamic disturbance affect performance?

Wind tunnel tests show that flush-mounted handles can reduce the aerodynamic drag coefficient (the well-known Cd) by between 0.005 and 0.015 points—significant when considering that a modern car might have a coefficient of 0.25. This reduction may seem small at first glance, but in modern aerodynamic design, every thousandth counts—especially now that electric cars are proliferating and many people remain concerned about their driving range.

You will better understand the importance of aerodynamics if we tell you that, at highway speeds, more than 70% of a car's energy can be used to overcome air resistance (depending on wind strength and direction, of course). In this scenario, reducing aerodynamic drag by half a point is akin to freeing the engine from an invisible burden. In terms of numbers—specifically regarding electric cars, which make the most use of this technology—this modest aerodynamic improvement translates to an extra 5 to 10 kilometers of range, depending on the model. This additional margin is appreciated on long trips and serves as an incentive for brands to try to offer greater range than their competitors.

Does this mean that flush door handles are just as important for internal combustion engine cars as they are for electric cars? The answer is that the reduction in air resistance is identical in both cases. However, the practical impact differs.

In a gasoline or diesel car, most of the fuel's energy (around 60% to 70%) is lost as heat through the exhaust and radiator. Furthermore, the front end of these cars requires open grilles to cool the engine via the radiator, creating considerable turbulence. In this context, reducing door-area drag offers a tangible benefit regarding fuel consumption—perhaps saving a few tenths of a liter—but the overall result is overshadowed by the inherent inefficiency of the internal combustion engine.

In an electric car, however, more than 80% of the energy stored in the batteries is utilized, and the front end lacks the massive grilles typical of a rally car. With a generally more sculpted body, any small protrusion—such as a door handle—contributes a larger percentage to the total drag. Therefore, while this helps reduce fuel consumption in combustion-engine cars, in electric vehicles, minimizing energy consumption and maximizing range become top priorities.

Many don't like the retractable door handle design...While it might help to give EVs a sleek exterior, flush-mounted door handles haven't been universally loved among drivers. Those found on the Tesla Model Y are manually opened by pushing in the larger section of the handle mechanism. Meanwhile, the Hyundai Ioniq 5 makes the handle accessible when the key fob is near, automatically popping out — though you can also utilize an emergency key found in the fob and manually press the handle inward to expose a mechanical lock. All of these different methods makes it difficult to figure out the manufacturer-specific quirks unique to each hidden handle.

While drivers might eventually get used to these quirks, passengers might fumble with what should be a simple task. Evidently, changing an easy-to-understand mechanism that's been a part of vehicles since the 1920s doesn't go over well with everyone. A 2024 poll conducted by GM Authority asked whether the Blazer EV should get classic or flush deployable door handles, and 64% of voters were in favor of traditional handles.

Even among those who are comfortable with how retractable handles work are finding new problems, with Tesla owners across the country complaining about their malfunctioning door handles. Some of the chief concerns include drivers being unable to open or close the doors with a dead battery. That's not the only issue, as YouTuber The Ioniq Guy showcased in a video where the handles failed to pop out due to being frozen in place.

Critics of the retractable door handle feature on many of today's EVs might be happy to learn that they're being scrutinized by officials, too. Due to safety concerns about emergency situations in which these door handles could hinder rescue efforts, China has banned certain retractable handles. That ban is expected to start in 2027, and it means that automakers will have to include a mechanical alternative so the doors aren't completely reliant on power to operate for the Chinese market.

Stateside, there have been tragic examples of these retractable door handles hindering rescue efforts. As reported by Bloomberg, off-duty firefighter Max Walsh came upon an EV crash and was required to break the window because the door handle failed to function. While he was able to pull out the driver, the driver's wife remained trapped in the vehicle for an additional length of time. This left her with severe facial burns and permanent respiratory damage, which could have been minimized if the first people at the scene were able to quickly open the doors.

As a result of growing reports focused around these retractable handles being an impediment in an emergency, the National Highway Traffic Safety Administration has become involved. Select Tesla Model Y doors are being examined by the agency, and in response, the automaker is reportedly working on a redesign.

So, while they may look very stylish, the real reason behind them lies in the battle against the wind. And this is a battle for which more and more manufacturers are trying to refine their designs.

Flush-mounted car door handles are becoming increasingly common because they improve vehicle aerodynamics and give cars a sleek, futuristic appearance

Main Reasons for the Trend:

• Better aerodynamics: Sitting flat against the car body, flush handles reduce wind resistance and aerodynamic drag by roughly 0.3% to 1.5%.

• Increased driving range: For electric vehicles, minimizing drag saves a small but measurable amount of energy, helping to slightly extend battery range.

• Modern aesthetic: Automakers use them to create clean, minimalist exterior lines that make vehicles look high-tech and advanced.

• Industry influence: Pioneered widely by brands like Tesla, the design quickly became a status symbol for modern luxury cars and electric vehicles