Aside from the ink capsules and higher voltage (though still very low), E ink is almost identical to LCD and probably slightly easier to make. There's a TFT (which can have a larger footprint, since it doesn't need to be transparent) on the back, an LC or E ink capsule layer, and an ITO electrode. Dead pixels are almost always caused by damage or defects in the TFT.
I wouldn't say it's artificially out of reach, though- setting a line up to produce large panels is a high opportunity cost. If anything is artificial about it, it's that you presumably can't buy E ink capsules yourself. With enough effort you might be able to separate the top glass from an LCD TV, dissolve the LC, and replace it with E ink, but I have no idea how you'd do that. No promises it wouldn't burn out the TFT immediately.
False. E-ink film, especially color, is definitely more complex to get right than LCDs.
TFT: Thin-film transistor
LC: Liquid crystal
ITO: Indium-tin oxide
LCD: Liquid crystal display (though this one's widely known).
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The answer would be "chiplets" of course, assembling bigger screens out of smaller ones. At the hobby leven, I think something decent could be built out of a few second hand kindle screens, if you plan the seams as part of the aesthetic.