Leaf springs are designed to reduce vibrations and shocks during dynamic operation of vehicles. However, leaf springs can experience various types of damage, such as breakage or fatigue, which can lead to suboptimal suspension performance and potential damage to other vehicle parts. In this manuscript, we explore the possibility of enhancing chamber clearance in leaf springs as a potential design solution to tackle these concerns. We propose a development approach that involves simulation-based design using CAE (Computer Aided Design) software and FEA (Finite Element Analysis). The development presses commence with creation of a comprehensive 3D design for the leaf spring. a meticulous evaluation of initial design is then undertaken, and improvement is made. Following this design optimization on chamber dimension, the prototype is manufactured and tested using method simulation static, simulation dynamic, vibration test, and durability test. The result of the study shows that simulation result of fatigue lifespan, it’s increasing 180.000 cycles to 1 milion cycles. The vibration test on sinusoidal road shown the vibration of prototype is not change compared with the original leaf spring. Therefore this study contributed to enhancing the leaf spring durability without decreasing the comfortability of the suspension.