It would be great if you could upload your latest design scaled down to your 3 part mini-board files so that we would have the proper scaling for the inner structure!
3DimensionalTools.com Komodo XL
It is such a pain to create the honeycomb pattern. It takes all day to make a minor adjustment the way I do it now. I'll have to look into ways to generate patterns with variable widths in Solidworks. I know it can be done, I use a gear generator that pulls from a spreadsheet. Maybe I can reverse engineer that method and apply it here to make some variations.