It cost 1.7 cents to make a penny this year, and 8 cents to make a nickel
washingtonpost.com
washingtonpost.com
Coins last much longer, 25 years compared to 6 years for a dollar bill. So, how much do they really cost in the long run is what showing in the second chart.
Basically, despite the fact that bills last 6 years, it's still cheaper to replace them.