For one, I know of the ROI expected for the USB stick...thing is I went from "jack shit" bitcoin income to "some" so as my first little bitcoin investment there was some existential/sentimental value in that for me, but lets get serious.
Yea, the USB miners have a terrible ROI window. But they're cheap, so people can buy one or two for fun and not care about it. Anyone serious about turning a profit from mining probably isn't buying the USB sticks. (don't get me wrong, I think they're pretty cool and am considering getting one just for fun, but I'd consider the purchase price a loss rather than an investment)
As to your saying FPGA is more expensive...depends. That is my current area of research. Why do you say this for sure - designing integrated circuits is very expensive. Laser cutting transistors is not easy and is a trial and error type thing.
I don't know much about FPGA design but I know that they're complex chips and that the per-chip cost is very high compared to other ICs. For example, the x6500 FPGA miner uses two Spartan6 LX150-3FGG484C FPGAs and gets 350-400 MH/s total. Each one of these FPGA chips costs US $175 on Digikey:
http://www.digikey.com/product-search/en?mpart=XC6SLX150-3FGG484C&vendor=122A Block Eruptor USB (ASIC chip + all supporting circuitry) was about US $100 in btc before they went out of stock. And that's the super-inflated-due-to-demand price of right now.
I know there are probably more efficient FPGAs out there now but you're going to need to get the price down a couple orders of magnitude and also reduce power consumption to make them competitive with ASICs.
FPGA is essentially a programming task. I also think FPGAs can be made to "scale" better. That is, adding continually more units to the whole system to heighten power without diminishing returns (incidentally the USB sticks kind of have this property which is another reason I was attracted to them despite shitty ROI on first sight).
This isn't a function of the ASIC or FPGA hardware but of the support circuitry. Bitcoin mining is embarrassingly parallel and doesn't require any communication between individual mining chips/devices/whatever. Each mining device just needs to communicate with a host capable of supplying work and this can be via USB, Ethernet, CAN Bus (linking multiple units to one host), or any other communication protocol. I personally like the direction that Avalon, ASICMINER blades, and hopefully KNC are going with standalone networked miners. This removes a central point of failure and provides for more reliable mining.
Well my thesis is simply this: hardware companies like BFL or ASICMiner will always take care of themselves (cannot blame them of course). But that means that still, as it was in the era of GPU dominated mining, the miners who jimmy rig their own shit will benefit from doing so. By avoiding the hardware developer middleman, a miner can control his/her own destiny, take advantage of timing to get deals (e.g.surplus auctions for FPGAs), and circumvent the "timing dilemma" faced by anyone buying new ASIC hardware which amounts to trying to predict the future to decide if buying or preordering is good; further FPGAs can be designed to scale up without end.
You may be a more efficient (i.e., more profitable) miner by doing more work in terms of building your own rigs but you're never going to be able to compete with people using current technology if you're using last-generation technology unless you have unusual circumstances like a pile of free FPGAs and/or free electricity. "Jimmy rigging your own shit" is still definitely a reality but it's most likely doing something like ordering Avalon or BFL (lol) chips and assembling them onto a board yourself. I'm not arguing with the premises of this point; doing more work yourself and thinking outside of the box exactly is how you can be competitive since lots of people aren't willing to go that route. I'm just saying that this mentality shouldn't mean restricting yourself to subpar technology.
Thank you
No problem, sorry if I'm coming off like an ass. :p