One example of this is the hood. The previous generation had a beautiful clamshell hood that wrapped down around the sides. Opening the hood made the front end almost look like an open-wheel car. But it was expensive to make in one piece, and the entire piece had to be replaced if any part of it was damaged.
The C5 has a more conventional hood, with seams running along between the fenders and the hood panel. Not as pretty, but substantially cheaper to repair.
So, $900 for a headlight? We need to strengthen (or better align) the incentives for carmakers to reduce component costs.