As you've already discovered, it'll be in the millions. Nothing says you CAN'T do this, assuming you can secure the funding. However, you need to keep in mind your competition: China.
I can have ten 50mm x 50mm boards made for under $10 + s/h from China. I can have three of the same board made through OSH park (who also outsources to China) for the same price. Or I can have a single one made at a company that's 100% based in the US, for a little over $300 (price based on a September 2012 quote.)
There are places in the U.S. that can make PCBs for much less than that. Albeit, it takes a bit of searching around. I've done the homework, because I refuse to support the downfall of the American economy & workforce just to save a few bucks. — I need to start a thread with links to reasonably priced American PCB manufacturers that people can use.
China has the raw materials locally, they don't need to import anything (from afar). This is why a lot of the electronics giants are in Asia (besides cheap labor.) Companies based in the US (or anywhere else for that matter) have to import everything ... 99% of the time, from those Asian countries. Someone, somewhere, has to pay for that. So, it's either we outsource it all for cheap, or we pay a premium. I choose to outsource, as does a lot of other US companies ... Apple being a big one.
Actually, the U.S. (and other countries) exports many of the raw materials to China, and then imports the finished products back in. Where China prevails is in labor costs (and lower overall cost & standard of living). What I made in one day as a Union Journeyman can pay an entire assembly line to work for (at least) a whole week in China. And, since most workers are forced to live, sleep, & eat at the manufacturing compounds where they work, there is no need to pay the workers "extra" for those expenses that almost everyone in other countries would have. Well, that, and the Chinese government artificially devaluing their money to keep the exchange rates in their favor....
Yes, China has a huge advantage for now. But, that's why we need people working on new business models that may help balance things out.