My idea was to create a 3D object that represented how the company had grown over their 4 years - My first thought was to create a 3D ornamental sculpture - but I wasn't happy with the results and it proved problematic to print out. So, I decided to go with a custom Lego set.
The first step was to create the bricks - this was actually much harder than its sounds and it makes you realise how fine and consistent the tolerances are real Lego pieces! Building the model (in Google Sketchup) was relatively easy - the hard part was getting the sizes right to allow for the material when 'clicking' bricks together.
The interlocking worked well and the model could be printed at normal resolution without supports.
With everything ready, I purchased some white lidded blank boxes, and had the slip-cover graphics printed at high res. And here is the finished results!