Yes, you've alluded to it. You don't seem to be quite clear on the concept of "BS, bring proof to backup your statements".
Aluminum cans, Plastic bottles. Different process, marginal cost differences.
And a flow jet can shape hard aluminum. Do you know what a flow jet is ? You don't make "aluminum malleable". It's actually pretty soft at room temperature as far as metals go and the flow jet can easily cut pieces without having to warm them up first. Using water.
So far, all you've come up with is that the processes are different. We know, no one argued they were the same. You have yet to back up your disputed claim of costs though beyond pure conjecture.
And again, at the volume of material/units made, we're talking cents. Not 150$.
Problem is, all we have to work with is logic - until someone who has access to specialized - and perhaps slightly confidential - information pipes up.
Logic would indicate that if an milled aluminium unibody was as cheap to make as a molded polycarbonite one, then a) it would have been done before, and b) other entry level manufacturers would be using the milled aluminium block process.
1) The cost to Apple to
develop their aluminium unibody process would have been non-trivial. Up until that point, no other laptop maker was using the process so everything would have had to be developed by Apple (and their partners) from scratch.
On the other hand, molding polycarbonite is a common process, and any number of factories could bid on an Apple contract, with no major development needed.
2) Even now, when the aluminium unibody process is common knowledge, no entry level laptop by another maker uses it. There is a huge marketing advantage to create a cheap Mac Book Pro look-a-like. Yet, a cheap aluminium unibody laptop is not in wide circulation - if one exists at all. There are, however, all sorts of polycarbonite (and other plastics) cheap laptops.
Those two points above would indicate to me that the aluminium unibody bit costs more to make than the polycarbonite bit.
One other cost needs to be factored in. Even if the "per-unit" cost is pretty close, Apple (and partners) still need to recover the cost of the research and development of the aluminium unibody process, plus the cost of building a purpose built factory. The polycarbonite development costs have already been recovered since this is now a standard and widely used process.
Just some more idle speculation....