Re: High Resolution Bitmap Export (perhaps via slicing)
Why not tile it as Mike has suggested, most printer drivers will allow this and you can print them to your printer driver and save them, then do your worst in PS. There are other methods which I have used in vinyl banners and that is Posterize at least that what it was once called: http://www.blockposters.com/
Like Mike again I would have chosen the PDF method which works for me. I thought that the line thickness was only a problem if you used a size under 0.5pt when exporting to PDF, might Google that point. Never had gradients or as you mention transparencies becoming smaller would check your advance settings in your Objects tab, use Custom DPI and make it a denominator from scale so that you have at least 120 DPI after scaling up. Have a try and at least you can check it in PS if you have enough memory to load PDF or better if you have Acro. Pro.
Design is thinking made visual.
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