I hope somebody with relevant knowledge can answer this question, please: what % of the costs is "physical cost per unit" and what % is maintaining the I+D, factories, channels...? In other words, if a chip with 100x size (100x gates, etc.) made sense, would it cost 100x to produce or just 10x or just 2x? Edit: providing there wouldn't be additional design costs, just stacking current tech.
Why would 100x something only cost 2x to produce?
>what % of the costs is "physical cost per unit" and what % is maintaining the I+D, factories, channels...?
Without unit volume and a definition of the first "cost" in the sentence no one could answer that question. But if you want to know the BOM cost of a chip, it is simply Wafer Price divided total useable chips depending on yield where yield is both a factor of current maturity of node and whether your design allows correction of defects for usable chips. Then add about ~10% for testing and packaging.