Re cost of sets: Trek fans have always gotten gouged out the wazoo on dvds. Trek is one of a handful of shows whose season sets routinely MSRP for over $100.
Most are $35-50 at most.
And my stock answer, having chatted to some DVD marketing people, is:
Shows like "The Sopranos" have no special effects budget. The costumes can be "off the rack". The sets and furnishings can be hired from stores. It's a cheaper drama to make.
"Star Trek" is a quality product, highly coveted by its many fans. It is *not* necessarily price gouging to have a higher cost for something in high demand. These prices are well researched for the marketing plan. When they get the price wrong it either sits on shelves or flies out the door.
The reason why Star Trek, in DVD boxed season sets, were originally at such a high price point was
to temper demand. If the price was originally lower, or equal, to other series, demand would be such that the stores could not keep it in stock and there would be anger from all points
(Remember the "Mini Beanie Baby riots in McDonald's stores? Trucks being held up? Demand overwhelmed supply, because the items were so cheap but highly desirable).
Tiered pricing means that the first wave of a release is at maximum. Diehard collectors buy it. Then a few months later, the recommended retail price drops to the second tier. More people can afford it. About a year later, it drops again. Now lots of people can afford it. Then off to bargain tables. Everyone can afford it. By then, a new, improved product, with new bonus features, comes out at Tier One. And so on. Then the fans scream "Double dip!", but forgetting that it's been several years since the previous release, packaging styles have changes, etc. Stores don't
want to carry old, stale stuff. So without
new versions, "Star Trek" would simply go "out of print".
Trek is more popular than "Stargate", "Babylon Five" or "Battlestar Galactica". So the price for Trek is usually higher. CBS shareholders would not want to see their quality product being given away at bargain prices when they know they have the popular product. And DVD manufacturers, warehouses and retailers could not adequately meet demand if
everybody who wanted ST could afford to buy it on Day 1.