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A three-step vehicle development process for crashworthiness in the frontal impact test mode is proposed in this paper. The three steps are: (a) System identification, (b) Initial Component Sizing and (c) Detailed Analyses, System Integration and Optimization, which suggests the use of FEA methods to do detailed analyses, system integration and design optimization as applicable in the later part of the process when more vehicle details are known. This paper discusses this process and the results achieved. Limitations inherent in this approach are also identified and discussed. The emphasis is on the development of the structural aspects of a vehicle for a high star rate performance in the NHTSA NCAP impact test mode.