I made a quick feasibility study for 16bit Dings. We probably need about 32 bits to make it smooth, but is there a simple icon editor that could save into 1's and 0's ? (I just used emacs picture mode, but it's a bit of a pain to work with 1's and 0's...)

I also added an overlap parameter so that OpenScad doesn't complain if 2 cubes just share a single edge. Overlap can be really small. You may pick up this idea and integrate it with the original code in some way :)

OpenScad code may need to be improved. It's working, but again, it's just a test...

See the original OpenSCAD Bitmap Fonts Module: http://www.thingiverse.com/thing:2054

Warning: Printing the test example is difficult. Use small filament and slow speed. Else, increase block_size (which is 1 = 16mm) to 1.5 or 2. I used 1.5 (24mm) for the one in the picture.