After a few prototypes and gathering feedback from friends and some strangers, we picked a path. We are manufacturing the pieces using a laser etching machine.
The designs are etched out of boards we hand paint. Once etched, the pieces are cut from the board. We then flip each piece and place them back into the now cut board; using the board as a jig for placement. We then etch the back side of the board.
Here are some new pieces fresh off the laser etcher. You can see they have a green side and a red side. The only piece which has the same color on both sides are the Castle pieces.
Above is a sample of finished pieces.