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You lost me a little to be honest. I'm not following your aluminum sheet sandwich detail with a 90* crease somewhere? I don't think the aluminum sheet is really going to add much flexural rigidity in a sandwich of two thin plywood sheets, especially in the long direction.
Or is the Aluminum sheet going to go in the backrest area, and the 90* degree crease is at the transition from vertical backrest to horizontal seat area? So the sandwich is the connection detail for the aluminum vertical to plywood horizontal?
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