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Did you do track the yield vs force curves, this would be really telling as I would expect your units to be quite a bit stiffer in side by side comparison with OEM. Marketing approach on that one with chart overlays of stock vs yours would be illustrative to the customer.
Also, looks like you don't have complete epoxy coverage on your glue up process. Is this on purpose to mitigate the squeeze out mess? Epoxy is not fun to clean up while trying to keep everything else neat and tidy.
We used copious epoxy in solar manufacturing. But a much different type than this application. That type is temporary. Managing the squeeze out was a major engineering undertaking during development due to it being so difficult to cleanly and consistently remove the excess. Automation helped a lot in the end once we got the robots. But the programing took a lot of iterations and proper jigging to make it robust. Entirely different process, but learned epoxy is difficult to cleanly manufacture with, especially in process development phase where every technician has a different technique.
Interesting thread OP and nice to see the epoxy to lug interface fail, and not the carbon fiber tube to epoxy interface. Even after the 10 ton press fail, should be able to slap some gorilla glue back on there (garage tech here) and be right back in business after some sanding prep, cleaning and 24 or so hours.
My last question would be is the lug interface powder coated or raw metal? That might be intellectual property, but I gather the lug would be strongest with a clean metal interface rather than a powder coated for no intermediary bonding between surfaces to count on. That looks like powder coating to me exterior to the lug, if it is anodized, ignore powder coat comments.
Regardless, it's plenty strong I'm sure. Saw a nice engineering discussion on this one to comment one. Great looking product, and super reassuring to see the engineering work being done to validate the work.
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