HI Georgehifi
I have no doubt you experienced what you say as I can see you have written a enthusiastic response. AS one who's been in audio a lifetime, I have been completely convinced by a demo I discovered later was a flawed. I too have heard some crossovers I do not like, especially the digital kind. I do believe digital DSP can be neutral, Weiss is a good example but its SO expensive. I also believe Class D can be good, example is Theta Digital, also quite pricey.
The science on this is quite clear: the passive arrangement introduces a large array of significant artifacts, all measurable and audible. Active also has some artifacts, but far fewer and more difficult to measure and hear. The reduction of audible errors in total is the goal of properly executed active design. Its a holistic design approach if you will. Solve the biggest issues first and then work to get the rest down. Distortion is the enemy, and once inside the driver, whether created by the driver itself or what comes before is impossible to remove. How about we prevent its creation? The speaker company I'm associated with pursues this goal though engineering in every move they make.
DSP is not an inevitable "must have" part of an active design. Well executed actives are available that are 100% analog, input to speaker output, with high end discrete variants available for those with bigger budgets.
Brad