I recently read an article about a new Class D audio amplifier module with excellent harmonic distortion and noise performance. I’ve always associated Class D with low quality.
What is the current state of the art? Can I consider building small amplifiers using inexpensive, high-quality Class D chips? Or is this limited to very expensive equipment?
Apart from what is now almost "niche" applications in audio (some HiFi or instrument amplifiers), most amplifiers you'll see these days are actually class D, from your mobile devices to multi-kW stage amplifiers.
Low THD is not a problem with "modern" power MOSFETs and proper sigma-delta converters. The tricky part is mostly about EMI, and output filters require large inductors with proper specs that can also be pretty expensive depending on the max output power. There's a small TI app note as a starting point:
https://www.ti.com/lit/pdf/ssztbo2The typical achievable THD+N for a good implementation is around 0.01% over most of the audio spectrum, which is certainly not as good as what we can get with a class A amplifier, but apart from low-power applications, class A amps are not really practical. Class A power amps are bulky, draw a lot of current and heat up like crazy. The more common class AB can be better than a good class D amplifier in terms of THD+N, while not as good as class A, but as others have said, except if you need a power amp for measurement purposes, your own ears are unlikely to tell the difference. Below about 0.1% THD+N, it becomes hard to tell just by listening. Also, however low the THD figure is, once it's connected to actual speakers, you'll rarely get anything lower than this - 0.01% - and that is with high-quality speakers.
As to the module you mentioned, they claim "0.0002% THD+N at 100W", which I highly doubt can be true, in general for a class D amp, but all the more given its apparently very compact form factor.
I'd be curious to know what kind of IC they used and see real measurements.