All those fancy caps everyone was ogling over? Yeah, NOT CHEAP. The number of PCBs they are using is also high. I think you are underestimating the cost of that board design with all high end components. It looks closer to a design used for high end analysis than production consumer hardware.
The rumors were that Sony was running into significant design issues with the PS3 and started pulling people from all over the company to fix things with a cost isn't an issue philosophy, and it certainly is reflected in the design and component selection.
FWIW, I think they are underestimating the cost of the heatsink/fan design as well.
Aaron Spink
speaking for myself inc.
Thanks for the analysis but i disagree with this.
All Playstations are hailed as a mark of engineering beauty. I heard of more PDA failing than PSP shipped at half the supply. Playstations have great reliability outside the random optical DRE, and you can prevent DRE by putting effort to maintain dust congestion. Same goes with Nintendo hardware.
Consoles should not die of PCB components failure. I am not sure if we should be forgiving and encourage that kind of shoddy work...