I feel that there are a lot of designs that guys want with parameters that they want that are unrealistic, many based upon questionable understanding on why and how things work. I think that to really work with some of the complex speaker situations that those requests entail, the R&D to provide the requested cabinet that functions to expectation would end up costing well more in time and effort than most people could afford or want to spend.
In some instances (maybe more than just some) you may very well be correct regarding unrealistic expectations on the customer's part. It would then be up to the specific builder to explain what could & couldn't be achieved, at least without the considerable additional R&D that you mention & the associated expense. IMHO, LDS would handle those conversations very well & in almost all cases would be able to, at the very least, come pretty darned close to what the buyer wanted employing established R&D. And if Don thought the buyer's expectations remained unrealistic, I think he'd very politely turn down the business. And possibly he'd even refer the buyer to a competitor he felt might better address his needs. He wouldn't want to ship any product that he felt would disappoint.
But probably in most instances (possibly the overwhelming majority), the customer doesn't have super intricate/detailed specs that he wants. Many times he just wants great tone along one generally established line or another. But they want it with superior drivers/components & their associated performance, lighter weight, smaller footprint/form factor, & superior construction/fit/finish. Maybe he'd also like many cosmetic options not available commercially. All this (with maybe the exception of the cosmetics options) is exactly the high end makers' stock in trade, LDS included.