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Context: Stalk lodging causes up to 43 % of yield losses in maize (Zea mays L.) worldwide, significantly worsening food and feed shortages. Stalk lodging resistance is a complex trait specified by several structural, material, and geometric phenotypes. However, the identity, relative contribution, and genetic tractability of these intermediate phenotypes remain unknown. Objective: The study is designed to identify and evaluate plant-, organ-, and tissue-level intermediate phenotypes associated with stalk lodging resistance following standardized phenotyping protocols and to understand the variation and genetic tractability of these intermediate phenotypes. Methods: We examined 16 diverse maize hybrids in two environments to identify and evaluate intermediate phenotypes associated with stalk flexural stiffness, a reliable indicator of stalk lodging resistance, at physiological maturity. Engineering-informed and machine learning models were employed to understand relationships among intermediate phenotypes and stalk flexural stiffness. Results: Stalk flexural stiffness showed significant genetic variation and high heritability (0.64) in the evaluated hybrids. Significant genetic variation and comparable heritability for the cross-sectional moment of inertia and Young’s modulus indicated that geometric and material properties are under tight genetic control and play a combinatorial role in determining stalk lodging resistance. Among the twelve internode-level traits measured on the bottom and the ear internode, most traits exhibited significant genetic variation among hybrids, moderate to high heritability, and considerable effect of genotype × environment interaction. The marginal statistical model based on structural engineering beam theory revealed that 74–80 % of the phenotypic variation for flexural stiffness was explained by accounting for the major diameter, minor diameter, and rind thickness of the stalks. The machine learning model explained a relatively modest proportion (58–62 %) of the variation for flexural stiffness.