I'm making a couple assumptions here, but I don't imagine I'm far off. First, the MiniRig will use an array of singles PCBs, similar to the current setup. I would guess that the future SC MiniRigs will go in the same cases as the current MiniRigs, which probably cost BFL well over $100 in the small quantities they buy. I'm going to estimate power draw for 1TH at 500W-1kW or so, so there's going to be a pretty beefy power supply, as well as each of the 25 single boards carrying a 12V to Vcc power supply. Add on assembly and test costs, and I don't think a small outfit could reasonably get Minirigs out the door for less than $1000 with any kind of profit.
Well, considering their minirig SC will sell for $30K, some of those assumptions make sense. But once difficulty has gone up enough to require prices per GH to go down by >10x or 50x, it will make equal sense to redesign for cost efficiency and not have 25 daughter boards with their own power circuitry etc.
Anyway, this discussion is missing the big picture. Even if you are right and prices would bottom out above $1000 per TH, thats still, what, 500x lower than today? And therefore, difficulty would be ~500x higher. Good luck estimating the ramp on that and earning back the investment of your minirig sc.
I think they priced it competitively enough that some of those fears should be assuaged, but there's still a huge amount of risk involved especially given BFL's penchant for missing deadlines and long lead times. I don't think it's really possible to estimate the effect on the network these will have. You're probably just as well to bet the money on whether Pirate will default or not. If they do collect the preorders to add 100TH to the network and ship out after the block split, you might have a 4 month ROI on your $30k with $10BTC and a profitability decline of 0.5/year. That seems pretty reasonable. If they ship 200TH worth of hardware in 6 months and then another 600TH in the year after it and if BTC stays at $10 it would take a year to pay off your investment, not counting having your money in limbo 6 months waiting on hardware. If they ship 400TH, you'll never see your money back.
Pull out your crystal ball and channel Miss Cleo, it will be about as effective as trying to estimate profitability in the next year.
A redesign of the board might save some on the costs, but justifying a new ASIC will depend on BTC price in the future. BFL might be able to tweak some extra performance out of their current design, but a large jump forward in power would likely require a redesign on a smaller process and the new mask set to go along with it. The first mask set is justifiable because it is such a huge leap forward over existing designs. Spending another $1M in a year or two to increase performance by a much smaller margin will be a much harder decision though, I would think price would have to go much higher for that to be worthwhile. How soon after this hits the street do you think we'll see a refresh?