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You could probably fab it onto an ASIC, which avoids the non-free software part (aside from the fab itself). So still way cool.
Open source fpgas cost up to $10 per chip, $17 if you want the big chungus 256 pin one with lots of extra memory and logic blocks. You can get pcb printing services for like $7 per board but I think I paid less than that last time I built something.
I’m pretty sure custom made ASICs cost orders of magnitude more than that.
For one, sure, but I’m guessing prices come down quite a bit once we’re talking larger numbers, like hundreds of thousands.
But those are really good prices though.