90nm to 65nm shrink is a quit big shrink. nvidia managed to get the 8800 chip from 484 to 334 mm2 down with the 90 to 65 nm shrink. so if they manage to get the same gain of roughly a third they will get out more than 30% more chiips from each wafer.
when you add that the shrinked chips probably will have a higher yield of chips running at the needed clockspeed too you might end up with 40-50% higher output of usuable chips per manufactoring process.
but to see how much money that actually saves we would need to know how much a rsx in 90nm costs atm.
also as said before they also might be able to save on mainbord size, colling and such things too.
so every chip shrink is a big step in the profitability of a console, thats why companies try to get them done as soon as possible.
but with nvidia being a fabless copmany they have to rely on companies with fabs for hire (like tsmc http://en.wikipedia.org/wiki/TSMC) to have the 65nm process up and running and the required quantities available.
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