1. Get samples FIRST.
And get them before you put much effort into your design/theme -- because what you find in chip samples may sway or alter your design direction. For your purposes, I'd order at least two sample chips (one weighted, one unweighted) of each CPC clay mold that appeals to you (there are at least 10). In addition, I'd order ceramic samples from GOCC, PGI, OWPS, and ABC -- at least 2 per vendor, so you can check both feel and sound when adjacent. To do it really right, you need at least 8-10 of every combination. Smart money is that you will select one of the many clay molds offered by CPC, but it's not a given.
2. Get ideas from existing chips and sets.
Spend many hours (literally) viewing different chip sets and designs in the photo galleries here and on ChipTalk. Make note of what appeals to you (and why), and what doesn't (and why). You will find these notes to be most valuable during the next steps.
3. Hire a chip designer.
Take your rough ideas for chip face/inlay artwork to an accomplished and proven chip designer. The cost is minimal when compared to what you'll spend on the chips, and the positive results of doing so cannot be overemphasized. There are several excellent designers here to choose from.
4. Select your chip colors and edge spot configurations.
Spend many hours in the Chip Design Tool, trying different combinations that match your theme/ideas/tastes. Get feedback from users here. Fine-tune. Rinse, repeat.
5. Don't rush it, get it perfectly right. No bonuses for speed or shortcuts.
Designing and building a once-in-a-lifetime chip set (lol @ that concept around here) takes time. Done properly, it takes a LOT of time, AND patience. Speed kills.
Somewhere along the line, you will likely be forced to make some tough budget choices. Spreading the costs of a high-end set over the lifetime(s) that it is used and treasured makes it easier to spend additional monies to get what you really want. Rare is the person with buyer's remorse for spending too much. More common is the person who "wishes I had done xxx for the extra $$". Don't be that guy.