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I didn't think that his cost was rolling in development kits, and since we're talking DIY then "bulk" is not really a factor. DIY mean batch or single... else you're not exactly D'ing IY.
I'd love to know his "second time around" production cost. One MAJOR savings area would be the IGBT drivers. Build them from scratch and save major coin. Those things are a niche market electronic device with high standards of reliability - read: expensive.
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