Did you know that it can take anywhere from a week to 10 days for an artisan to expertly carve just four knights for a chess set?
The creation of a chess set might sound like a straightforward task, but the process is anything but simple. There are many different design and manufacturing processes involved, from reproduction chess pieces to one-of-a-kind chessboards, which we will explore throughout this article.
Here at Regency Chess, we specialise in traditional wooden chess sets, and whilst we offer some fantastic themed chessmen made from crushed stone resin and stunning chess sets carved from alabaster and marble, we’ll focus mainly on the production of our wooden chess pieces and chessboards.
The Initial Design
To begin the creation of any chess set, we first need to consider several aspects. Some initial points to think about in this planning stage are:
- The wood types to be used – Ebony, ebonised boxwood, rosewood, acacia, etc. The more exotic the wood type used, the more expensive the chess set.
- The chess piece design to pursue – Staunton, themed, ornate, modern.
- The size and weight of the chess pieces – This will determine the size of the chessboard, too.
- Chess set type – Travel (ie folding board), luxury, ornamental, etc.
A note about chessboard square size and king base diameter pairings: The ideal ratio for a chess king’s base diameter to the size of a chessboard square is generally 75-80% coverage. This means the base of the king should cover this amount of the square’s width. This ensures the pieces are well-proportioned and provides enough space for adjacent pieces without overcrowding the board.
Prototyping
Once the design specifications have been settled, the next stage is to create a prototype showcasing what the set will look like when in full production. This prototype is the best way to determine whether any changes need to
be made and can aid in checking the pairing of the chessmen and chessboard, ensuring the wood types complement each other and that the proportions are correct.
Crafting the Chess Pieces
After the prototyping has been completed and any necessary changes have been made, the chess pieces are now ready to enter full production. Providing the chess set has not been created as a one-off, this is the most timely stage in the process and involves a skilled touch in hand-carving each piece to meet the strictest quality standards.
To begin the carving process, the logs from the trees are cut down into smaller wooden blocks to make them easier to handle and to ensure uniformity in the wood grain. As wood is a natural product that is prone to warping and cracking, the wood is first seasoned, which can involve air drying or kiln drying; both of these processes work to bring the moisture content of the wood to around 6-8%, making it stable and less prone to deformation over time. The wood blocks are also inspected before carving to rid any pieces with flaws such as knots or irregular grain, as these can affect the carving process and potentially lead to defects such as cracks later on.
The production is then split into three main stages:
- Lathe Turning – Pieces that do not require intricate detail, such as the pawns, are shaped using a lathe, where the wood is rotated and tools are used to carve the basic shape. This method provides a great way to achieve perfectly symmetrical shapes. You’ll find that even on pieces such as the knights, the bases are sometimes turned on a lathe first.
- Hand Carving/Detailing – Intricate designs and details such as the crowns on the queens, and the face and mane of the knights, are carved by skilled artisans using specialised hand tools like chisels and knives to achieve the level of detail that we come to expect throughout our range. It’s typical for one set of knights to take up to 10 days to be completed due to the time it takes to carve the details, and these are usually assigned to a specialist craftsman who focuses entirely on these pieces.
- Finishing & Treatment – This is the final stage of production, where each piece is sanded to remove imperfections and ensure a smooth surface, which is then treated with oils, waxes and sealants to enhance their appearance and protect them from moisture. Any additional weighting that’s needed is added into the base to meet the specifications set out in the design, and finally, the bases are felted.
So, when you next sit down to play a game of chess with one of our sets, just remember that someone (potentially halfway across the world!) has sat there for weeks on end turning a rather mundane block of wood into a majestic work of art.
Crafting the Chessboard
99% of the chessboards that we sell are constructed from wood veneers, as opposed to solid wood. The production of these chessboards requires the utmost precision and care to ensure that each veneer aligns perfectly to create something that fits together seamlessly.
In the production of these types of chessboards, there will typically be at least two wood types used – one for each square colour – and potentially more if a boarder is introduced around the playing area. The process from start to finish involves:
- Cutting and Laying the Veneers – Veneers are carefully cut into thin sheets, often ranging from 0.5-1mm thick. The pieces are selected and arranged to achieve a contrasting pattern and are glued onto a solid substrate, often made from MDF (medium-density fiberboard) or plywood, providing a stable base. These veneers are also applied to the borders and base of the board, with the base commonly made from a single sheet that may vary in colour and wood type compared with the rest of the board.
- Tidy-up – After the glue has dried, the excess veneer around the edges of the board is trimmed to ensure the board’s edges are clean and straight. The surface is then sanded to smooth out any imperfections and create an even texture ready for finishing.
- Finishing Touches – To finish the board, the surface is treated in a lacquer or polyurethane coating. This final step protects the wood and provides a uniform surface for playing on, and can be finished in both gloss and satin finishes. Some of the boards are fitted with protective felt pads on each corner as an additional measure.
Why veneers instead of solid wood? We sometimes get asked whether our chessboards are made from solid wood. Apart from a couple that we have since discontinued, our wooden chessboards are made using veneers. There are a few main reasons why we have found these types of chessboards to be superior:
- Solid wood boards are prone to warping and cracking, even when they have been seasoned, due to their size and shape. Veneers do not suffer from these defects, allowing them to be used in more varied temperatures without degrading.
- Solid wood boards can be very expensive, taking away the option for an affordable chess set from most people. Rather than using a fine sheet of wood for each square, they are crafted using an entire chunk of wood.
- Veneer boards are far lighter, making them easier to move around such as if you want to put the set away after each use.
The Fun Bit
Once the chessboard and chess pieces have been finished, it’s time to enjoy a game or two to put the chess set to the test!
For us at Regency Chess, this would also be our opportunity to come up with a fitting name for the chess set, and to pair it with a chess piece case and clock if needed. We would then photograph the set in all its grandeur for listing on our
website as a new product, trying our best to capture the wonderful details and natural beauty of the materials.
Whilst we haven’t delved too deep into each process of manufacturing a chess set, such as how the wood is sourced from sustainable plantations, the different machinery and techniques available for cutting wood veneers, or the years of skill that the artisans spend perfecting their craft, hopefully you now have a better general idea as to the processes involved from start to finish in the creation of a chess set.
