When it comes to peloric Cattleyas, they can only be so flat. I think it comes from the usage of Cattleya intermedia v. Acquinii. This is a peloric form of the species which gave rise to such hybrids as LC. Mari's Sing and Lc. Prism Pallette.
I think it is due to extra tissue causing the three lip or peloric trait. This extra tissue I believe makes the petal not only to look like another lip but it fails to let the petals develop a real flatness.
They often have spectacular color but the form leaves something to be desired. It is a trade off, color for form. Lindsey, just enjoy their beauty and accept the form is what I am trying to say.
Variation from year to year is all cultural. Average temperature, heat stress, average night time temperatures, amount of light, water uptake can all effect the shape to some degree.
I still think that peloric Cattleyas are spectacular flowers and not amongst the easiest plants to grow and bloom either. GREAT JOB for blooming yours regularly!!!