Thanks for the feedback, Tom.

There are many options to combine things that can cause situations that are difficult to solve automatically in 3D setups.

Do you have this in mind?
https://www.maxon.net/en/cinema-4d/features/thicken-generator?srsltid=AfmBOorf1T6n-4-HTF3qt-BwHe91cSF_vNFxO8jF5x7arq5cA4pVG3lU

Here is a 20-second clip that showcases the problem:
https://stcineversityprod02.blob.core.windows.net/$web/Cineversity_Forum_Support/2024_Clips_DRS/20241104_Thicken-Problem-Bevel.mp4

Since you wrote that you are not in love with weighting, even though you did a great job here weighting it, the solution would be, as shown in the video from the website, that the Bevel would be part of the model and is already driven by the overall weighting. With this, there is no sudden "pop-in" at one specific angle of the Bevel added geometry or the flip when the edge changes 90º.

Here is my suggestion on a simple level:
CV4_2025_drs_24_ANcb_01.c4d

Anyway, I understand this should have an option to tell the tools, do this, and avoid that. I get that.

This leaves me here, as I can't change the code (of course not), to share this link, so you have your wish directly shared with Maxon. Fastest and most observed inbox for suggestions:
https://www.maxon.net/en/support-center
"Share Your Idea!"

Sorry that I can't give you a better answer.

All the best

Thanks a lot for the feedback, octomber!

Yes, there are certainly a lot of tiny little tricks that need to be shared. Having done the timestamps for the past 11 episodes for the Hands On Character show, I believe we can quickly fill a third season with tips and tricks while going deeper into the tech. But I fear those solutions are more interesting when needed during a project, not presented in a more extended series.
With that being said, I hope to fill those gaps that are naturally left and learn from everyone's questions I got over the past nearly two decades.

My best wishes for your project.