Intel gets more $/mm2 from their fabs than NVIDIA could ever dream of. Why would Intel do such a thing, except perhaps to fuck with AMD?
Uttar
They will do it when they start losing serious marketshare and design wins. If they don't, then that means AMD's ATI aquisition and Fusion did nothing more than allow AMD to potentially take marketshare from NVidia, VIA, etc which ironically is cannibalizing their own market, since those companies marketshare is predominantly AMD core logic chipsets. They'll get revenues from their own ecosystem players (whilest kicking their own partners out of IGP the market), but they won't really decrease Intel's share. AMD's primarily business is CPUs and unless they can get more AMD core logic into the market, they will not have any cross-sell for AMD CPUs. So AMD will want to continue to increase its marketshare vis-a-vis Intel, and if they continue to do this, and if the process accelerates with Fusion, Intel is going to take a hard look at its IGP.
So far AMD has been doing well in grabbing marketshare (prior to Core 2), and by corrolary, AMD's chipset vendors have been doing well too. Especially in mobile, AMD has been increasing marketshare, and Fusion has the greatest potential in this market to go head to head and beat Centrino platforms. If they beat Intel at perf/watt by good margins, they have a huge chance of getting a future Apple contract as well, since Apple is fixated on perf/watt now.
However, Intel and AMD's marketshare gains in some markets, like mobile, have seem to come at the expense of smaller players (Transmeta, VIA, etc) and not Intel. Intel increased its share by 3% this quarter, and AMD increased by 1.3%. Once Intel and AMD have sucked up all of the marketshare from the smaller players, AMD will have no way to gain more share except by taking from Intel.
(BTW, the fortunes of Transmeta and VIA declining also signal their buyouts. As I have mentioned, Transmeta would be a good fit for NVidia to attack the ultra-portable/handheld market, as traditional x86 chips don't compete these, and TI's competitors are vulnerable. Transmeta chips can be made to run ARM code with Transmeta code-morphing, so there is another nice benefit to stealing existing vendor contracts)
As for $$/mm and fabs, I would not envision Nvidia producing chips at TSMC for Intel, rather, I would imagine Nvidia customizing and selling a design to Intel, which its engineers in partnership with Nvidia would then refactor for their own fabs, either for IGP, or later, on-die integration. High margins are great for ROI/EPS, as long as you have marketshare, but if you start losing significant marketshare, you can't make up for the loss of earnings by increasing margins further, it won't scale. Even at 100% margin, they'll come a point where your earnings trending downward.
If you look at Intel's Centrino roadmap, even Montevina is only going to have a GMAX3000 with 10 shader pipes instead of 8, clocked at 475Mhz. This will put them around X300SE performance, maybe marginally better. ATI's Fusion is likely to integrate a cut-down R600 which will probably spank the GMAX3000 bigtime. Even if it went with an integrated X1300/1600 cut-down it would still spank it.
Intel has long benefitted from the fact that people who buy its IGP products basically don't care about 3D performance and for the most part, run 2D desktop apps or non-perf sensitive 3D games. However, that may change with Vista, as many of the new technologies in Vista leverage 3D, and Microsoft is pushing apps to utilize more and more 3D functionality for their UIs via XAML/Avalon. For the first time, poor 3D performance could be visible to 2D non-gaming desktop users.
At first, this probably won't be very visible as Aero Glass isn't all that taxing on 3D performance (although heavy use of compositing blending will strain bandwidth at high resolutions) However, as more and more apps start to integrate 3D animations into the UI ala OS X CoreAnimation or MS Avalon, the I think it will start to become visible in store demos, as AMD Fusion powered Vista desktops will appear more Fluid and Snappy. Never underestimate the effect that fluid desktop animations have on people's psyche. Whenever I show off OS X animations like fast-user-switching, the desktop gadget flip-and-zoom-ripple effect, or FrontRow activation, I always get an initial "aww...cool"
OS X is in fact a preview of Vista's effect on 3D. OS X looks less fluid on a Mac with Intel G950 vs ATI Mobility X1600, especially at high resolution. My friend as a MacBook with G950 hooked up to a 24" monitor, and it shows obvious hiccups compared to my wife's MacBookPro with X1600 on her 24".
Basically, if AMD starts to threaten Intel Integrated marketshare, Intel will have to go shopping. Simply pouring more man-power on GMA architecture isn't neccessarily going to fix the problem, and they will have a limited time window to get competitive. If AMD doesn't threaten Intel integrated marketshare, it means Fusion is a failure, and AMD's acquisition of ATI was a questionable move in the long term, and merely of interest to short-term earning acquisition and cannibalization of their own IHV ecosystem.
I would keep an eye on the mobile market, where perf/power, size, and cost are absolutely critical. ATI has the potential to either be a disruptive platform here, or to fail spectacularly. A power-efficient CPU core with adequate performance on-die power-efficient GPU and video playback would be an obvious value proposition to notebook manufacturers struggling to increase battery life and performance. Intel doesn't have any solution in this area today, and their notebook IGP sucks ass. Centrino is a nice platform, but it's lacking graphics. Next-gen notebooks will need to run Vista well, and handle HD-DVD/BR playback efficiently, while at the same time, satisfying people's desiring for ever decreasing weight, increasing battery life, and smaller form factor.