> If you assume Starlink satellite $/W
Why would you assume that, given that high power output is not a design goal of Starlink?
ETA: power is absolutely important for Starlink. SNR is very important for shannon capacity and satellite systems are often limited in this respect.
Anyway, my point is that Starlink is not primarily designed to harvest as much solar power as possible the way data center sats are. I'm sure they're not making it inefficient on purpose, but what you're suggesting is like using the cost/W of a solar powered traffic camera to estimate the cost/W of a solar farm. Yes, they both use solar power, but they have entirely different design goals.
Cost is a different matter of course, but it seems incongruous to me that after being confronted with the fact that your power density assumptions were off by a factor of 2x you would continue to insist ChatGPT's weird assumptions about manufacturing costs scaling linearly with mass are accurate. As was already pointed out upthread, even if all the calculator's other assumptions are correct they can turn a profit if they get the per satellite cost (excluding the cost of the GPUs) below $2 million. I think the only big question mark here is launch cost.