In an effort to efficiently manufacture quality products, numerical models and empirical measurements are used to predict (virtually) the performance of a hearing aid. Finite element analysis is used to study multi-physics processes such as thermo-mechanically induced stress due to heat flow from soldering, acoustic and structural interactions due to transducer vibration, and mechanical shock failure due to drop testing. Following a synopsis of hearing-aid anatomy, the presentation will show numerous animations depicting results from the virtual prototypes.