I have seen small scale manufacturers having their name in circuit boards that they design. SparkFun has their own pcb boards. Do they have the same setup?
I still would like to know how you etch and drill.
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.)
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.
There are places in the U.S. that can make PCBs for much less than that.