@ColinHaynes haha - yeah you have certainly taken it to the next level! I'll check out a few of the mosaic resources you mention in your blog post, very interesting. Your results look great!

I have not considered 3D printing the blocks, very interesting idea.

I've been using 38x38 node base plates which corresponds to 38x38 pixels for the 1x1 bricks, or 19x19 pixels for the 2x2 bricks. The 38x38 plate is 12" x 12", so using 2x2 bricks that will yield a 24"x24" area for 38x38 pixels. That is a nice size for your typical 32x32 pixel sprite size found in many 8-bit era games.

I've yet to build the 2x2 brick version, it is sitting here waiting for me to i) figure out a good camera setup to capture a time-lapse, and ii) find time to physically build it.

I've just been using Aseprite in grid view as a guide for the layouts, no mosaic software, though I've only made single-color images so far. I did look at the official Lego mosaic maker and found it pretty limited.