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Posted by andsoitis 3 days ago

Evolution of car door handles over the decades(newatlas.com)
33 points | 50 comments
boatloof 5 hours ago|
The mechanical flush mount car door handles are because shaping that divot into the steel is much more complicated then punching a hole, and especially aluminum is many times more complicated and expensive. Audi was showing off their technical expertise with creasing aluminum with unlimited money in their bodywork before dieselgate, and that was pretty much peak for car body technology.
garciansmith 3 hours ago||
This article contains a nice chart of different types: https://www.theautopian.com/what-is-the-goat-door-handle-des...
lylejantzi3rd 6 hours ago||
This is a great video by SuperfastMatt on the engineering behind and evolution of the Tesla door handle.

https://www.youtube.com/watch?v=Bea4FS-zDzc

VladVladikoff 2 hours ago|
Even in the new version it seems like there is no fallback method for a failure.
mcculley 6 hours ago||
I am bemused every time I use Uber and the car has some flush-mounted door handle that I have to figure out. When exiting the car and closing the door, I end up leaving fingerprints I would not have left if the handle had been designed by someone who had been in a car before.
jjtheblunt 6 hours ago||
agreed on fingerprints, though i bet the rationale is coefficient of drag, not lack of experience with various door handle designs.

in the article, it shows a Magna-Steyr handle on a Mercedes Gelaendewagen, which looks like those on the Ineos Grenadier, and not very different than the ones that Ford uses on various trucks.

that contrasts with those on Audi and BMW evs, for examples i see often, where the CoD is a stated spec for ev shoppers, and the handles have motion to them, but are flush (but not Tesla vanishingly flush). Weirdly, some Porsches (intimately related to Audi...just read the shared parts) use flush handles and some the protruding handles with an actual handle.

i admittedly pay an unusual amount of attention to car componentry, sort of a hobby really.

AlotOfReading 5 hours ago||
The additional drag is negligible. People have been producing "racing doors" with handles for decades. They focus on cutting all the other features of the door like weight and mechanical complexity instead. It's an even more irrelevant consideration for consumers, who could save far more fuel by changing how they drive.

Flush handles exist as brand differentiators. They're a "futuristic" feel-good feature that consumers want, like engine noise, tablets, and colorful dashboards.

zamadatix 3 hours ago|||
It's about more than just one thing alone. E.g.

https://media.landrover.com/new-range-rover-sport-press-kit-...

https://usa.infinitinews.com/en-US/releases/2025-qx80-press-...

kube-system 5 hours ago||||
All of the things you mention are considerations that every automaker considers. Product design engineering is simply an exercise in weighting those factors, among many others.
AlotOfReading 4 hours ago||
I'm saying flush handles aren't about drag, not passing judgement on whether those other factors are bad.
kube-system 4 hours ago||
Drag is absolutely one of those factors. Yes, it only contributes a small amount to the overall drag profile of the vehicle, but a vehicle is a sum of its parts ultimately.
AlotOfReading 2 hours ago||
It's not a meaningful factor in decisionmaking. Manufacturers went on an aerodynamics optimization spree in the 80s after the fuel crisis. Concepts like the Ford Probe actually dropped handles and all other protruding surfaces in favor of things like electrical touch panels. Seriously, go look at the photos. Even the pillars are flush.

The production vehicles designed after these concepts often used flush pull-up handles for aerodynamics. Those handles later disappeared in favor of the more reliable pull-bar handles we're familiar with because improved CFD made it clear how minimal their benefit actually was for the tradeoffs.

Of course, even if we accept that all the mechanical complexity of flush handles is necessary for aerodynamic reasons, it's not the only alternative to pull-bars. Look at the Volvo EX60 for an example. Designing a flush handle is hard. Tesla spent years working on it. It's not something undertaken for negligible aerodynamic benefits.

jjtheblunt 2 hours ago||
What tradeoff is there between pull-up and pull-out handles?
AlotOfReading 1 hour ago||
They can't take as much force and they're less reliable. Sometime in the 90s-ish a new test came into force that greatly increased the impact they had to take without unlatching and continue working. The pull bars made it easier to meet because they're secured on both sides.

The pull-up latches also caused issues for people with long nails. In some places spiders liked to nest inside them. Places with snow had issues with a sheet of ice forming over the entire panel, an issue that also occurs with modern flush latches.

PearlRiver 1 hour ago||||
Exactly it is not science but purely cosmetic. Which for some reason makes HN mad but guess what people choose cars based on how they look and how they are marketed! There has never been a rational man. Spock is not real.
WalterBright 5 hours ago||||
People who race stock cars will even dip body panels into acid to make the panels thinner. Anything to reduce weight!
recursive 5 hours ago|||
> It's an even more irrelevant consideration for consumers, who could save far more fuel by changing how they drive.

These are not in conflict. The energy you save from drag stacks with the energy you save from "learning how to drive".

hshdhdhj4444 5 hours ago|||
Yeah, but making opening doors a puzzle to solve is an incredibly terrible trade off.

And that’s before we consider the other aspects of these door handle designs that make the cars a death trap.

kube-system 5 hours ago|||
They add a tiny bit to the efficiency and/or range, they look cool (e.g. serve a gee-whiz marketing purpose), and safety evaluations in the markets where they still exist don't penalize them -- up until now they've had very little against them.

Maybe as legal and reputational backlash spreads the pros will not outweigh the cons. But someone designing a car a decade ago, marketed towards early adopter types, would have had no reason not to.

And I say this as someone who hates these handles designs personally.

recursive 2 hours ago|||
The death trap claims come from the internal affordance, which seems to be totally independent from the exterior one.

I have a car with a "novel" handle situation. (Ford Mustand Mach E) The door is operable from the inside with a dead battery. Maybe this particular one isn't as challenging as some of the other designs, but calling it a "puzzle" definitely overstates the case. I think it took me maybe 4 seconds to figure out the first time.

kevin_thibedeau 1 hour ago||
The Xiaomi SU7 has notably threatened the lives of many of its occupants because rescuers couldn't open the doors from the outside after power loss from a crash or fire. This car is partly responsible for China's new safety regulation banning flush handles.
AlotOfReading 4 hours ago|||
I'm not presenting it as a conflict. I'm presenting it as a revealed preference of how much consumers actually try to optimize fuel use. There's significant reductions to be had completely for free (or even with savings by purchasing smaller, cheaper vehicles). And yes, the savings from flush handles are too small to show up in the MPG number.
recursive 5 hours ago|||
Those that care about fingerprints on their car seem like they're different people from those that drive for Uber.
chankstein38 3 hours ago||
Or someone who had to open their own car door before lol
jiehong 3 hours ago||
Nice, but it would have been better with more pictures to match the description IMO
cafard 4 hours ago||
Kids today miss the chagrin of damaging a protruding door handle, and the entertainment of one of their elders entirely removing one against some obstacle.
eth0up 8 minutes ago||
I've a bone to pick with the title, which euphemises degradation.

If they evolved, one might assume they'd survive more than a few years.

My last two vehicles have been Toyota and Hyundai, both of them having multiple broken and malfunctioning door handles.

Every time I get into a commercial* or antique vehicle, I long for the solidity, surety and hardness of the dark ages when things were built to last.

Driving semis, I'm well acquainted with automobile 'evolution', and all but a few are hardly worth entering. UPS trucks, Mac, some others still make stuff for adults, but International, Peterbilt, even Kenworth are using sillyputty for parts. Consumer vehicles, to me, are the antithesis of evolution. And for all the wondrous eco tech, their merit is contested by landfills, downtime and piles of repair receipts.

Not that eco couldn't work, but the way it's been introduced, in the US, has been replete with cut corners and outright scams. An old truck pre-DEF still runs far more reliably than anything new on the road. Volvo has done reasonably well with trucks, but no new truck can stand to the old ones. CAT!

Door handles are symptomatic of the disposable infrastructure we've built our new country on, and come hard times, when folks can no longer afford a new HVAC system every 8 years at 12 grand, coupled with everything else falling apart around us, we'll be longing for the dark ages again.

Thankfully it's not everything. I just bought a pair of Knipex pliers, which should make it well through the century.

For the young, or majority I presume, if you can suspend your contempt of a less fuel efficient steel monstrosity, hop into an old vehicle from the 70s or earlier. Close your eyes if needed, but just feel around a bit. You'll feel honest engineering. Not as safe, but there's something obnoxious anyway about being too safe and cozy trundling around in a big bulbous plastic bubble. We didn't always drive unaffordable fluorescent pillows.

RickJWagner 3 hours ago||
When I was about 20, I had a well used AMC Spirit.

Stylish, good gas mileage, decent performance, it was a great car. It had one fatal flaw, a weak linkage in the drivers door handle.

The linkage included a small plastic clip that didn’t quite align properly. It would pop out of place periodically, making the door impossible to open. I became adept at taking apart the door from the inside and popping the pieces back into place.

I once returned to my college dorm after a snowstorm, the car got stuck in the snow. I had another trick for this situation, I’d ease the clutch out ( leaving the back tires spinning slowly ) and would exit the car, pushing it by hand. When the wheels caught and the car started creeping forward I’d jump back in and drive off. ( Foolish, I know. I was 20. )

Well, once I had both mishaps at once. The car got stuck, so I got out to push. The door handle broke, locking me out of my car with the engine running and the wheels slowly turning!

Praying fervently, I ran to my dorm room, got my spare key and went in through the passenger door to stop the engine.

It was a memorable day.

VladVladikoff 3 hours ago||
Website crashes mobile safari?

Edit: correction it seems to be crashing on my adblock.

jacobgkau 1 hour ago|
I was expecting some mention of the Dutch Reach (internal handles that are sort of backwards to force car users to look in the direction of possible approaching pedestrians or bicycles behind them while opening their door), but I guess the article's focus wasn't quite on that type of detail.