Aerojet, the other solid rocket engine company, warned of this in the 1960's. They built large single-piece solids, including the most powerful rocket engine ever built, the mighty AJ-260-2. The AJ-260-2 was part of the evolved Saturn program. Stage 1 of the Saturn I would be replaced by this one, huge, solid rocket motor. This would reduce the cost to operate the unit dramatically it was felt. After Challenger, they again offered the skills to manufacture the single-piece solid, but were rejected.
Incidentally, the AJ-260-2 is still sitting in Florida, all but forgotten in an abandoned warehouse.