A Chess Set Like No Other: Sebastian’s Masterpiece in Aluminium and Brass

We’ve been running our project competitions for some time now, and are always so proud to share the creativity, skill, and ingenuity of customers across Australia. From custom trailers to a satellite ground station to a full suit of armour, the competition showcases what’s possible when quality materials meet great ideas.

This year’s winning entry is something truly special: a precision-machined chess set crafted from aluminium and brass by Sydney-based mechanical engineer Sebastian. Designed and manufactured over 18 months using advanced CNC machining, the project combines engineering excellence with striking visual design.

Meet the Maker: Sebastian, Mechanical Engineer

Sebastian is based in Sydney and works as a mechanical engineer at the University of New South Wales (UNSW) Kirby Makerspace, where he designs and manufactures parts for researchers. His role gives him access to high-end manufacturing equipment, including CNC mills and CAD/CAM software (which played a major role in bringing his chess set to life).

Before stepping into his current role, Sebastian was also part of the Redback Racing, UNSW’s Formula SAE team, where he helped design and build a race car.

“I bought a lot of steel from Edcon for the car project, as well as for my current job and personal projects as well!” Sebastian explains.

Inspiration: Learning Through Making

The idea for the chess set came about when Sebastian’s workplace acquired a new 5-axis CNC machine, which is a highly capable but complex piece of equipment.

“We got a new five-axis CNC machine, which we’d never had before, and I wanted to learn how to use it properly,” Sebastian explains.

“I decided to make the chess set as a learning project, because it has a lot of different pieces that required me to learn the most complex aspects of the new machine.”

Design and Planning: CAD, CAM and Perseverance Image:

The design process began in CAD software, where Sebastian modelled each chess piece and board component in detail before programming the CNC machine using CAM software.

Designing the full set took between three and four months, and it was far from a straight line.

“It was a very iterative process. I’d design something, machine it, then realise something didn’t look right or didn’t work, then go back and change it,” Sebastian explains.

Because the project was completed entirely solo, every adjustment, redesign and refinement fell to Sebastian. One of the biggest challenges was designing parts that could physically be machined on a five-axis CNC mill with limited clearance.

“If I made anything too tall or too steep, the machine just couldn’t reach it when it tilted over.”

Materials: Aluminium and Brass from Edcon Steel

For the chess pieces themselves, Sebastian sourced aluminium round bar and brass round bar from Edcon Steel. The material choice was both aesthetic and practical. Aluminium and brass are easier to machine than steel and produce a far superior surface finish straight off the CNC mill.

“Aluminium works really well for the white pieces and brass for the black pieces, as the contrast is great. Steel would have been much harder to machine and wouldn’t give the same shiny finish,” he says.

In total, the project required around three metres of round bar for each material, plus additional aluminium sheet and brass sheet for the boards.

Sebastian visited Edcon Steel’s Revesby store to purchase his materials.

Building the Set: Precision Takes Time

From start to finish, the build took approximately 18 months. Most of the work was done during lunch breaks, after hours, and in between casual jobs and study.

The machining itself was highly precise, but not without setbacks.

“Sometimes the machine would detect a potential collision halfway through a part and just stop. You’d end up with a half-finished piece and have to either redesign it or scrap it and start again.”

Despite these challenges, the final chess pieces required almost no post-processing.

“The chess piece you see in the photos is the as-machined finish. I didn’t polish the pieces at all, I just clear-coated them with lacquer to prevent tarnishing.”

The Finished Result: Functional Art

While the concept of a chess set isn’t new, Sebastian believes the real standout feature is the pieces themselves.

“’I’m really happy with the pieces as they are so unique, and just look really good.”

“Each level of piece has more facets: 5 sided pawns, 6-sided rooks, bishops and knights, a 7-sided queen and an 8-sided king. The two colors of pieces also spiral opposite directions for an aesthetic contrast.

Inspired to start your own project?

Whether you’re machining precision components like Sebastian or tackling a weekend DIY build, Edcon Steel has the materials and services to help you get it done right. With a huge range of aluminium, brass and steel, custom-cut options, and stores in Brookvale, Revesby, Blacktown, Bathurst, and Orange, plus Australia-wide delivery, getting started is easy.

Explore the full range online or visit your local Edcon Steel store today.