Costs include double the amount of video RAM, a PCI-Express-Bridge-Chip, PCB cost and the contracts negotiated with TSMC.
According to the analyses I have seen, yes it does. If you go by raw silicon costs, Fermi is ~$150 (104 die candidates per $5000 wafer, 30% yield (I am being overly generous here, far less for a 512 shader part) gets you ~$160), add in $10 for packaging and testing, $20 for a PCB (lots of routing for 384b memory, but cheaper than GT280), $20 for board components, $25 for HSF, $10 for assembly, and $39 for 12 GDDR5 chips ($3.25 per for low bins, if they up the bin, add $6 or so). That gets you to $274 raw cost, no FOB, no profit, not assembly failures etc.
Then look at Hemlock. Silicon costs about $45 per Cypress die ($5000 wafer w/160 die candidates per (it is actually higher) @70% yield (conservative not estimate) ~= $44.6, real numbers are better than that), $90 for the pair. Add $7.50 per, $15 total for packaging and testing (no lid, much smaller die, far fewer traces, better dot pitch, less power, much lower package board count etc), $25 for the PCB (probably cheaper than GF100's but lets be negative), $30 for board components, $25 for the HSF, and $15 for assembly. Add 16 GDDR5 chips (At $3.50 per - one price tier up from Fermi's) for $56 and you are at $256.
I have a lot more precise numbers than that, but lets just say I am giving NV every benefit of the doubt and ATI a very negative spin on these parts. Also bear in mind that these numbers are before any profit is taken. Nvidia tends to mark up silicon by 100% from cost, so they would sell GF100 kits for $360 or so, ATI tends to take a bit less, but if they do 100%, it would be at $266 for the same kit. At that point, you are arguing PCB layers, board components, and HSFs.
I can make a good case for ATI having the cheaper of all of the above even after you take into account both chips. Part of that is the absolutely moronic choice NV made with regard to voltage vs amperage, did they go flat out insane? No, don't answer that, but it blows out their packaging costs, and likely will lead to some serious problems on chip longevity, especially in enthusiast parts where voltages are played with.
So, to answer the question, yes, ATI can make a Hemlock for far cheaper than NV can make a GF100. In fact, they can price Hemlock at the point where NV is in the red and ATI is making money, albeit a very slim amount. If you add in margins for the AIBs, disti's, shipping companies, and (r)etailers, things get much uglier for NV.
-Charlie