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@ffm
I'm not an engineer so all the following may be bollocks. Since the spokes run inward from the flange to the rim and are under tension, presumably the load they extert is not perpendicular to the hub axle. Could you improve the design of the flange by making it slightly cone-shaped so that it lies exactly in the plane of the spokes?
Edit: after all, rims have eyelets drilled off-centre so that the "point" at the flanges; why don't the flanges "point" at the rim?