WOW! Those are some cool looking boards rawnster. Are those available at mc master's or somewhere else. They look like carbon fiber from the pic.Thanks, Chad
For protoypes and small quantities you might not shorten your lifespan to do them in the garage on the bandsaw or if you are young and full of spunk, use a hacksaw.. but for large quantities I have found that taking them to a shop and having them knocked out on the CNC machine is the only way to go. If you make a career out of cutting and sanding circuit boards without lung protection it would probably not end all that well for you.
I haven't found any need for thicker than 1/16" as far as strength goes and I agree with everybody else that it is much more friendly than the the other stuff to work into the shape you want. I also prefer carbide tipped drills, it's pretty abrasive stuff.