the machine that "grows" metals via laser-melting from some type of metal-powder (almost dust) did produce really fine and smooth surfaces. even round or ramp-type objects didn't have the "steps" you usally get from with the sl-process and plastics, so i guess that would solve a lot of problems...
it won't probably solve the price-prob
but as they've shown me they are capable of doing 20x20 cm elements with their standard rig. maybe there's bigger sizes if they use a different base-plate.
and the process of laser-melting that powder is incredibly fast. it's really amazing seeing that little laserpoint tracing your objects..