A chess set laser cut out of acrylic with free templates.
Place the grid pieces on a 12×12 inch ~4.5mm sheet of acrylic in an 8×8 grid for the chess board itself. Because the acrylic glue can leave bubbles between pieces, I just left these unglued and loose. I like this a lot more, and makes it look a lot more haphazard and visually interesting.
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Using two of your favorite colours, cut out two sets of chess pieces and grid squares. Depending on your cut quality, the chess pieces may press-fit together (though hopefully not too tight, or they may crack), or you may have to use a little acrylic glue to seal them together.
Via: Make Via: Makerbot Industries