And another huge cost that is relevant to the TS's dream -- NRE (non-recurring engineering) costs. That has killed a number of these kinds of projects (even ones that were rationally thought out to begin with). People think that they will do all this in their spare time and often discover that they don't have that kind of spare time and that using what they do have for something like this amounts to an unacceptable opportunity cost for them.It depends on the stage of the supply chain. It seems the OP is is talking about 2 cents of sand in a silicon wafer to make a one dollar chip.
Your radio shack example, the finished "manufactured part" is a packaged resistor in a consumers bag on the counter next to a cash register. Counting only one raw material is foolish and not a standard to measure whether or not an enterprise is profitable. If it was, we wouldn't be talking nostalgically about Radio Shack -they would still be a profitable enterprise.
Unfortunately, manufacturing costs include, in addition to raw materials also include labor and energy. These threee items, Rams, labor and energy are typcially referred to as variable costs and are proportional to the quantity produced.
Even more unfortunately (especially for radio shack) fixed costs also exist. They can be (commonly are) much higher component in manufacturing costs. Interest on borrowed money, depreciation on assets, taxes, insurance, at the manufacturing location.
A boule of silicon can be converted into a pile of chips quite cheaply. But, doing it without a billion dollar Fab is quite a feat.
Also, a pile of resistors can be sold quite cheaply but, RadioShack couldn't compete with their network of brick and mortar stores when mailorder houses can do it cheaper -without the assets.
As for ole Radio Shack, I would have loved to see them stick around largely as what they were back in the 70's and 80's. I don't know if they could have made that happen by changing their business model so as to tailor to and actively foster and create the hobbyist community, perhaps even partnering with schools at all levels. I think something like that would have been what it would have taken, and I'm far from certain that it would have been sufficient. I would not be surprised to learn that they considered many possible paths including some along these lines and concluded that they weren't viable.