I don't remember the exact amount, but Gene Trimble recently posted that he had just ordered 16,000 $1 chips for the Palms and the cost was something like $1.06 each.
The days of casino quality chips costing .60 each is looooong gone.

I further doubt that you will see any $1 LE's being manufactured anymore unless perhaps they are part of a set.
As a matter of fact, if you are a collector of A/C chips, most recent releases have been $25's