I've been fielding questions about how to best cut OpenBeam, so we've done some testing. For hand tools, a good miter box and a good 32TPI hacksaw blade gives adequate results. Here's the 3D printed miter box from a few weeks ago:
Things to watch for: The extrusion should be secured from moving while it is being cut. For this, I use a De-Sta-Co hold down clamp, a fairly common clamp used in manufacturing engineering for tooling and fixtures.
The results are okay. It certainly cuts it fairly cleanly, but at the end of the day, it's still a hacksaw cut:
So, for anyone inclined, I've made available my Solidworks design file and the .STL file here. Files are released "as is", i.e. with no guarantees to work.
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