EMC uses the HostMot FPGA config where EMC handles all of the trajectory control and thus is capable of spreading the work across multiple contollers. We use the SoftDMC FPGA config where trajectory planning is done by Mach but the control is done on the Mesa card. So adding axes by adding multiple controllers is not possible. However, you can use one Mesa card for axes and another Mesa card for I/O. (I wrote an I/O plugin as well) Also, there is the 96bit 5I22 (8 axes and 48 bits of I/O) if that might be enough.
With the 5i20, you could do 8 axes and 24 bits of I/O with the motion plugin. Then you could add another 5i20 for another 72 bits of I/O with the I/O plugin.
The Mesa motion plugin is not tested yet, so it's not ready for prime time. I've been working too much.

Steve