A method of producing a vehicle includes determining the performance of aged adhesive coupons, which are subject to a worst-case scenario of manufacturing, aging, and stress testing. Virtual vehicle components are modeled using the performance of the aged adhesive coupons. The virtual vehicle components are then subjected to virtual mechanical forces to determine their virtual performance, which is then validated against the performance of identical real-life aged vehicle components subjected to identical mechanical forces. A virtual vehicle is modeled using the validated virtual vehicle components. The virtual performance of the virtual vehicle when subject to a virtual crash test is then compared against a predetermined standard, and the design of the virtual vehicle is considered feasible if its performance exceeds the predetermined standard. A vehicle is manufactured according to the feasible design of the virtual vehicle.