If I were your customer I’d be looking at commercial alternatives readily stocked, such as dowels or (if a hole through it, or some other objection, doesn’t matter) a roll-pin. If necessary modifying the design a little to be able to use such items.
An alternative to a band-saw would be a metal-cutting circular-saw or cut-off grinder, followed by a quick twiddle on a linisher to blunt the cut edges. (I spent eight years cutting machine-ready metal blanks, of all types, for a living… It’s a wonder it didn’t put me off model-engineering!)