I'll keep it short, forgive me.
• You keep ignoring the possible different contracts at TSMC for AMD and Nvidia
• you forget the PCIe-Brigde
• 70% Yield would in my books provide a much higher rate of stock than it is right now. IOW: I doubt that number
• HSF uses Vapor-Chamber, which should be a bit higher than your average heatpipe-radial-blower-combo
• Board-Design should be using far more complex circuitry, because it has to switch two chips within mikrosekonds
edit:
Probably add to that higher per-unit-prices for even the same components because of volume.
I have a fair idea of TSMC contract costs. Then again, if you are in a situation where there are massive shortages for ~2 years on 40nm wafer starts, you probably aren't going to give many discounts. ATI likely has the volume now on 40nm, so I really doubt that NV gets appreciably cheaper wafers.
You are right about the PCIe bridge, so add $15 or so, maybe 20.
I am aware of the cost of a vapor chamber, I know the two companies that make the OEM parts for ATI, and know many of the people involved at the cooler companies. ATI has almost the same wattage to cool as NV, and has a larger area to cool it over, both die and card. If you want to add $5 for ATI there, feel free. The official cost for the 4870X2 reference cooler was $15, and I was told at the time that some companies could do an internally designed vapor chamber for half that. The cost differential there is very low. Don't confuse consumer costs with OEM/ODM costs. You also have no idea what the production GF100 consumer card will use for a cooler, do you?
Board cost is mainly layer count. The power and signal pins to a single GF100 chip are likely much harder to route than the those to a single Cypress. 384 bit memory vs 256 are a major factor, as is power PER GPU. The PCIe lane count will be equal either way. You have a slightly longer board for ATI, and a much more complex board for Nvidia. Given the two, the GF100 board is probably more expensive. Anyone want to count the layers on a Cypress vs Hemlock board? Same? I don't have a hemlock here to do it with, but I would wager that Hemlock is a notably simpler board than GF100.
Anyone want to count the board layers on 3870 vs 3870x2, 4870 vs 4870x2 and 5870 vs 5970? Since they are all released products, can Dave tell us? Oh heavenly voice of ATI knowledge, answer our nattering technical minutia.....
FWIW, the board layer count from my CES pics seem to indicate a 14 layer board, but it is hard to tell if that is camera artifacting or real counts. It is a 14MP SLR, and I can clearly read the resistor numbers, so it is likely to not be artifacting, but it could be.
-Charlie