Rivian Automotive Inc. is undertaking a significant redesign of a critical component in its vehicle doors, specifically for its upcoming R2 generation SUV, in response to growing safety concerns voiced by both employees and customers. This move addresses potential issues associated with the current electric door handle design, which has become a focal point of scrutiny across the automotive industry following incidents where occupants were unable to exit vehicles due to power loss, leading to tragic consequences in some cases.

The planned revision for the R2 models, slated for deliveries beginning in the first half of 2026, will incorporate a manual release mechanism that is more prominently visible and strategically located near the electrically powered interior handles in the rear doors. This change aims to rectify problems that arose from a redesign of Rivian's existing R1 models last year, which saw the rear manual releases moved to a less accessible location. In the R1, occupants are required to remove an unlabeled panel and pull a release cord to manually open the rear doors from the inside, a process described as unintuitive and potentially difficult for children or older occupants, according to a complaint filed with the US National Highway Traffic Safety Administration (NHTSA).

Rivian stated to Bloomberg that "Safety is at the center of everything we do at Rivian, and R2 is no different." The company affirmed that the R2 will adhere to or surpass all Federal Motor Vehicle Safety Standards, including those for passenger egress during emergencies. The new R2 rear door mechanism and positioning are expected to mirror those of the front doors, providing a more consistent and user-friendly experience. While it remains unclear whether this updated design will be retrofitted to currently available R1 vehicles, Rivian noted it has not received any reported injury claims stemming from rear door electrical failures in its latest R1 models.

The broader context for this industry-wide concern gained traction after Bloomberg News reported on issues with Tesla Inc.'s doors, prompting US auto safety regulators to launch a defect investigation. Tesla, an industry leader whose futuristic designs are often emulated, has also acknowledged working on integrating manual and electric door releases to enhance intuitiveness in emergencies, although the locations of its manual releases can vary by model and be challenging to locate.

Experts like Michael Brooks, executive director for the Center for Auto Safety, emphasize the urgent need for NHTSA to establish clear standards for electric door handles. He argues that the absence of federal safety regulations in this domain places an undue burden on consumers to familiarize themselves with various emergency escape configurations across different vehicles, with potentially tragic outcomes in critical situations.

Rivian's decision also aligns with its ongoing efforts to reduce costs and streamline manufacturing processes. CEO R.J. Scaringe highlighted a "heavy emphasis" on eliminating unnecessary components and steps during a June 2024 presentation, specifically mentioning the rear doors as an area for component reduction in preparation for the R2 line. The original R1 design featured a more traditional handle combining both electric and manual components, with the rear manual releases being relocated in the 2024 refresh due to cost-saving and design considerations. At least one high-ranking executive within Rivian has reportedly deemed this previous decision a mistake, underscoring the company's commitment to prioritizing safety alongside efficiency in its evolving vehicle designs.