When designing our characer we created a single "box" shape and this would represent a single pixel of our character. We simply copy and paste the box for every pixel in the bitmap. This works great on smaller bitmaps, though on larger images we need something better.
Here is our character with all the pixels merged into one model:
Printing our character is straight forward, though getting him off the build plate can be a challenge. In this model we can use the Fillet tool in the 3D design package to round off the edges making the character easier to get off the plate with a knife or spatula.
Click the link below to download the file(s):
Disclaimer: All files are provided as-is without warranty of any kind.