It’s unfortunate that merging catalogs isn’t possible yet. Please consider this a feature request. Should I post it in the forum?
Most other Digital Asset Management tools—such as Lightroom, Capture One, and even Aperture—support this functionality.
Before I begin my large master archive project, I really need to think carefully about how to structure it: by country, by subject, or something else entirely. I don't want to do this work again, spent more than a week just to import these 1.000.0000 photos.
For what its worth, while there's not a singular "merge catalogs" function, you can do the following:
1) Check the "Search" box in the catalogs you'd like to move *from*.
2) Check the "add/Modify" box on the catalogs you'd like to move *to*
3) Use the Search function in Photo Mechanic and enter two double-quote characters in the Quick Search field to reveal all images in all Catalogs with their "Search" box checked
4) Once the search shows its results, go to Edit -> Select all
5) Then go to Catalog -> Include selected items
6) Once that is done, check the Add/Modify box for the catalog you'd like to move the images from (and uncheck it for the catalog you just added the images to), repeat steps 3 and 4, and then choose Catalog -> Remove Selected Items.
Of course, if you have Collections from the Catalogs you are moving from, this doesn't retain those, so maybe this doesn't work for you, but if you haven't created collections in them yet, maybe this is helpful.
I believe a customer has told me they have a catalog of over 7 million items. There's no hard limit on the size of a catalog.