We used Qubicle Constructor by Minddesk - a user friendly voxel editor that can create 3d models from pixel artwork.
In order to test workflow and ensure a smooth production we initially spent R&D time with the software creating a little robot. Then we went on to the GAME characters...
2D: Initially a 17x44 pixel image of a pirate was created in photoshop using the pencil tool.
Qubicle: Once the pixel artwork was imported in to Qubicle Constructor the pixels were given volume to become voxels within a matrix. From here Qubicle allows the user to select voxels and extrude them within the matrix. This means the model can be given depth and definition in 3D.
3D: Once the 3D voxel model is completed it can be exported as an .obj and brought in to 3ds max as polygons.
Vray: A simple Vray shader was applied, with a VrayEdgeTex used as a bump node. This creates a round corners effect without having to alter the 3D model in anyway, and keep polygons down.
The model is then ready to rig and animate, just like any other character.