AJ Sawyer

@Mongo, there's a lot of depth you could go here. I'm just going to start with something here... A good tool is "TheLaminator", I think there's a 30 day trial but a license is $29. This would give you apparent laminate properties from a stackup of composite lamina. There are some tabs for loading... which I think suggest to you a max moment if I'm remembering correctly. http://www.thelaminator.net/ You can use the above for getting laminate properties. For analysis of panels, Roarks Stress and Strain is the best accumulation of different loading conditions. Table 8.1 on page 189 is a good place to find scenarios. You can use these to get the max moment. https://jackson.engr.tamu.edu/wp-content/uploads/sites/229/2023/03/Roarks-formulas-for-stress-and-strain.pdf Composites typically fail in compression, so you can use these equations This is a great original paper from NASA that discusses theory. There is a lot of matrix math, so leaving the calculation programs to do the math is a great route. https://ntrs.nasa.gov/api/citations/19950009349/downloads/19950009349.pdf

Heck yeah. Here's a few youtube video examples of how they're made. .... and a more classic one.

That's an awesome composite structure! Mortise and tenon or tongue and groove. It's used a lot for optical benches and reaction structures. It's plenty stiff and strong. It just has to be designed properly to transfer loads https://markets.rockwestcomposites.com/aerospace-defense/structures/case-study-reaction-structure/

I've used this material to make reusable bags before. It's pretty easy and cheap to do by hand, no special equipment. The trick is one light brush coat before building up thickness (to avoid bubbles). https://www.reynoldsam.com/product/ez-brush/