I am sure this study has been done by automakers or public but I wonder what a 100 mile EV would cost to produce?
It depends if the automaker makes 100,000/year, or 1M a year. The curve (price per car vs number of cars produced) would look like an exponential decay. If a carmaker is certain it can actually sell 1M cars a year, it can set up production lines to build 1M/yr, and sell each one cheaper than if they only make 100,000/yr. This is what I understand Tesla is doing: setting up to build (millions? guessing) of "Model 2" that can be sold for $25k each. Nissan probably doesn't think they can sell 1M Leafs a year, but Tesla does, because they see lots of demand for their brand. High demand => confidence to invest in larger production lines => lower cost per unit. (Tesla is also re-imagining a car production line, designed expressly for EVs, theirs in particular).
Smaller EVs (smaller cars in general) are more popular in other countries. China has the
Wuling Hongguang Mini, which I understand is very affordable. Europe has the the
Renault Zoe, which is small but rather expensive. The
VW E-Golf was available in the US until recently (someone around here sometimes talks about his own). For anyone actually looking to buy a 100-mile EV, there are many affordable second-hand Nissan Leafs.
And the range reduction is probably not linear with battery capacity. For example if the battery capacity is reduced by 1/2 there is a significant weight reduction of the vehicle, less tire losses and all other things being equal better range. So I bet the range reduction is less than 1/2.
I think that concern can easily be addressed by the engineers. The weight of a car varies just as much whether it's carrying 1 person or a family with luggage, and I have yet to see a carmaker publish range as a function of how many people are in the car. A few data points
from here:
"For example, the Model Y (4,416 pounds) has a larger battery ... (1,200 pounds)."
"The heaviest EV battery is the Hummer EV [9,046 lbs] battery, which weighs around 2,923 pounds.
A Semi story: