Getting really off-topic. Alumnium isn’t brittle, that’s it. Regardless of your years of… Add this to the knowledge base. (Experience and knowledge are not grown linearly)
The concern really is to address hinge stiffness and cover flex in a coherent manner. (Just so you know, there are aluminium alloy springs, by design, made to flex with a given load, over and over. i.e. Just because something is made with aluminium, it doesn’t immediately means it’s unsuitable to flex)
You:
Also you.