Class D is cheapest to make but it is hardest to design...more complicated than any other class. Due to the development of faster switches, it is got a lot better..now Hi Fi grade class D amps are within reach..It will most likely replace class A/B and class B someday..say less than 10 years?...but not class A... It is way over priced now...and still have a lot of room to improve. It should be much better and cheaper where is gets very popular.
Class D is nothing new, I think the first class D engineering report was published in 1958. Other than faster switches. RFI/EMI interference issue have not been solved completely. There is still interference which can be aided by a speaker cable that works as an antenna, for example. Worst case will screw up TV and Radio signals. Using surface mount parts, good pcb layout, shielding and isolation would reduce most of the interference. The R&D would be costly. It is a good challenge to audio engineers. I am a hybrid and view the Hi Fi world differently. My destination changed because H.P. hired me before an audio engineering firm after college. I never involved with audio design again..lol..