Hahaha Phil, my forum name isn't as descriptive/accurate as yours. Guapoalto049 was my instant messenger screen name from middle school...sadly it stuck. I'd almost forgotten what it meant, it seemed much more clever when I was 11 and trying to impress the ladies
More rigid chitin is a neat thought, maybe like a Rhinoceros beetle! Speaking of that, is beetle exoskeleton tougher because its thicker or are there additional polypeptides?
Interesting question, the few recent articles and physiology books that I have read concentrate on the minutiae of chitin synthesis, because when entomologists master that, they'll be able to disrupt/block the process so that they can do what they like best, kill more insects more efficiency.
An earlier book, though,
Fundamentals of Insect Physiology by Murray S. Blum (1985) addresses your question in detail.
First, cuticular chitin formation always follows the same path (I described it here, once -- no idea why!) and ends up with the same poly-N-Acetylglucosamine. Also the all-important crystalline structure (chitin layers with different orientation from one crystalline layer to the next). does not differ beyond the three basic forms (c.f.!).
The layers have varying amounts of what i call "packing debris" between them, mostly broken off amino acid residues with small side chains, and it does seem that those insects with the heftiest chitin have the highest scores. Your rhinoceros beetle, Xylotrupes gideon, for example has 47 amino acid residues per 100 total residues, and other large beetles also score high, though the ancient common hawker dragonfly (it's out now, in Yuma) scores 64, while the pupa of the silk worm, protected by its cocoon, only score 21.
The problem is, though, that heavy, stiff epicuticular chitin tends to be rather brittle; not much of a problem for a beetle's elytra, but not so good for a mantid's tergites (it would not be a problem with molting, though, since the chitin does not completely harden until a day or two after ecdesis) so we shall have to work on something. Resilin, perhaps? You do realize, though, don't you, that if these experiments are successful, they will mean the end of life as we know it?