Anyway, I thought I'd load up Fasty's Astroboy model to see what it's like. The quality is amazing! I must have got it confused with the low-poly Quake 2 model that's around. Anyway, I'm sure I can't do better. I loaded it into Voxel3D but it looks like it can only be used as a reference model. With something that complex I'd rather not draw the voxels over it by hand.
So I did some more experimenting, and a lot of searching for 3D to voxel converters. I did manage to run one successful conversion, but I can only view the voxels, I can't split it into layers.
Then I had another look at Voxel3D and stumbled upon the Voxelize menu option. It seemed to freeze up for a minute, then it drew this:

Very cool.



So now I definately have a way to generate a 3D voxel map of Astro's head. The hard part is going to be tweaking the settings. I need to work out exactly how tall Astro's head is in Lego. And Lego bricks aren't perfectly square, something else I'll have to factor in.
I'll probably do his arms last. I don't know how to move the model's arms so I think I'll have to design them manually.
Right now I REALLY need a break from this.