NHTSA complaint #11737862

Owner complaint summary

Component: Exterior Door Handle (Front Passenger) Incident Description: A latent manufacturing defect resulted in the structural delamination of the interior chrome plating on the front passenger door handle. This failure occurred after the last use of the handle, creating a razor-sharp metallic edge that was not visible during a normal approach to the vehicle. Upon contacting the handle to open the door, a passenger sustained a deep laceration from this jagged metallic blade. Safety Hazard: The defect transforms a primary vehicle touchpoint into a concealed cutting hazard. The chrome skin peels and curls into a sharp edge without warning or visible signs of wear, posing an ongoing risk of serious physical injury to any occupant. Manufacturer Response: Tesla Service (Los Gatos) was provided with photographic evidence of the razor edge and the resulting injury. While acknowledging the injury, Tesla refused a safety-based "goodwill" repair, citing the vehicle’s age (2019) and the absence of a formal recall. Tesla further attempted to attribute this structural material failure to cleaning products, despite the vehicle being garage-kept and maintained only with pH-neutral enthusiast-grade soaps. Tesla has since refused further discussion. Request: This defect poses an ongoing risk of serious physical injury to any occupant using the handles. I am reporting this to assist in identifying a trend of material failure in 2017–2020 Model 3 chrome door handles.