As usual..... Extremely interesting.Whole it “can” be done, there are a LOT of practical obstacles that have to be overcome and each obstacle comes with a cost.
An example of an amp that can come pretty close is the SWR HeadLite.
It had probably the highest power density in its class, but after the first production run it was found to be more expensive to build than originally thought. It was a 3 dimensional puzzle inside, and the cost was a deterrent.
It was rated at 400 watts RMS into 4 ohms with a rich feature set. In fact, in order to achieve this, the power module had to be derated significantly and it proved to be more costly and difficult than it was worth.
One of the limiting factors is power density, how much power per cubic inch of chassis. Different class d and SMPS topologies have different machining power densities and in general the higher the power density the greater the cost (for a reliable amp)
200 watts at 4 ohms is pretty much the sweet spot for micro amps (at this time).
I own a 300 watts version of the amp. Should I consider I'm "beyond" the sweet spot?