We've alerady hit the point where a block has become 90% full, thanks to the popularity of SatoshiDICE.
The limit can be increased from the 500 KB max per-block in the software to 1 MB per-block limit in the Bitcoin protocol, reportedly.
To increase this to the level allowed by the protocol, is it just a client update for miners, or does it require a new client for everyone who needs to be able to accept blocks with the larger limit?