Whats and efficient way to bin pointclouds into voxels and calculate mean intensity?

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The voxel grid filter in PCL (Point Cloud Library) does almost exactly what you want: it bins point clouds into voxels and reduces the point cloud to one point per occupied voxel. I am not sure whether it also averages intensities; if not, it should be easy to add.

The PCL also has a CUDA version of the voxel grid filter.

If you don't get good answers here, try the PCL mailing list.

Lets use this thread to discuss good ways.

Just a warning about etiquette, before you get flamed: ROS Answers isn't a forum, and this isn't a thread. The ROS Answers format isn't really well-suited for open discussions; it's meant for questions that have a clear answer. That said, I'm not sure what a good alternative is; perhaps http://discourse.ros.org/ will evolve into that.