The cost of making money is just like the cost of making any product: you have research and development of the product, you have to figure out the process of making it which includes buying a lot of tooling and equipment, and then you have to purchase all the raw materials to actually produce the product. More complex products, like the $100 bill, will have a more complex manufacturing process which drives up the cost due to having to buy special equipment. They will also have more raw material inputs than a $1 bill, so that also adds to the cost.
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