"The results scaling of the static contact study was a little enthusuastic and the components appeared to pass through each other."
It's normal for the objects to slightly pass through one another in a contact analysis. Internally, contact is done using springs between the surfaces and the engine will iterate and adjust the spring stiffness to try and enforce the contact interface. However, it's impossible to prevent all penetration from happening, since doing so would require an spring with infinite stiffness.