Reinforced Polyurethane for vehicle suspension Strut Spacer Design

I’ve already 3-D scanned the upper seat of my vehicle’s front strut and now need two new spacers—38 mm and 46 mm high—that drop straight onto that geometry without machining or trimming. Both parts must be modeled in polyurethane and should present a smooth exterior so they slide cleanly into place and won’t trap dirt.

Strength matters more than shaving grams, so please build in ribs, gussets, or any other internal reinforcement you feel is appropriate while keeping overall height to those exact figures. I will provide the scan file in STEP and STL; you return production-ready CAD (STEP/IGES), native file, and a quick FEA snapshot confirming the design can handle typical load paths for a MacPherson assembly.

Deliverables
• Two CAD models: 38 mm and 46 mm spacers
• Drawings with key dimensions and tolerances
• Simple FEA report demonstrating reinforced strength
• Optional: manufacturing recommendations for casting polyurethane

If something in the scan looks off, flag it before progressing so we stay aligned on fit.