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Have Hasbro ever considered using joints like those seen in the Revoltech AY Batman's knees? It doesn't use the three piece ratcheted balljoint most figures on the line have but a simple swivel cut in the middle of the knee itself, with the sculpt allowing for a pretty good amount of range.
Peanut joints have never worked for the range nor the aesthetics IMO and it sounds to me like it'd be less work on your end if you found a way to implement it.
On another topic, how entrenched is the Amanat crime family within Hasbro?
From some Marvel podcasts nobody cares about I've heard and heard about, it seems like everything bad with Marvel today can be tracked down to Joe Quesada hiring Sana Amanat to run their content and character development department.