I wanted a clean modern looking staunton set, with smooth flowing lines. The King stands 4 1/8" (104mm) tall with a base of 1 7/8" (47mm) so a board square size of 2 1/4" or larger is preferable. I use a board with 2 3/8" (60mm) squares. I added a cutout area at the bottom of the pieces so you can add weight.
Additional piece height info:
King: 4 1/8" (104mm)
Queen: 3 5/8" (92mm)
Bishop: 3 1/16" (78mm)
Knight: 3" (76mm)
Rook: 2 3/8" (60mm)
Pawn: 2 1/8" (54mm)
I'd be interested in hearing what people think about the knight. I was really torn between the modern look I went with and a more traditional one that looks like a horse.
Note that the bishop doesn't have a cutout, every time I export one with the cutout in ViaCAD, the shape looks low res. I'll upload an updated one soon.
No support or rafts. I arranged all the main pieces and printed them in one print job. Then I laid out 8 pawns and printed them. Using a Replicator 2, the black prints out almost perfectly, while the white seems to print with some minor artifacts that you have to file off. Printing them individually seems to give the best results.