Why are flats more expensive than rounds? I am thinking of switching to flats on some of my basses, but want to try out like 5 different sets. One set is $27 (Chromes), but the rest are all around $40-$45 bucks for a 4-stringer set. 

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I am thinking of switching to flats on some of my basses, but want to try out like 5 different sets...
He hasn't been seen for 8-1/2 years so... good luck getting an answer.You posted this back in 2006. Have you been able to try those five sets of flats in the last 16 yrs? How did they work out for you?
I want to re-animate this zombie because it was never answered.
Any takers out there?.....057912
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^ This.I’ve always assumed the manufacturing process was more time consuming. Time is money.
Or because many of us prefer them-but still a smaller percentage than roundwound players, flats are produced in smaller volume=higher price.
Yeah, ^^this^^ Been playing basses with flats almost exclusively since 1968, mainly because I don't like the way round wounds feel. I have a wood rasp already, thank you; I don't need to buy more. I also don't like the way they sound. The finger noise is really annoying, too. And, finally - I have much better things to spend my old person fixed income on, than trying to keep 26 basses in new round wound strings. And much more funner things to do with my time, too. Even my guitars wear flats...More labor goes into making flats. Less flats are sold so manufactures lose economy of scale. The cynical reason they cost more? They last so much longer the string makers need to make more up front because they know they won’t see another sale for a while. My experience shows that I save money in the long run buying expensive flats. I burn through rounds on most of my basses, while my p bass sits there and says, “nah, I’m good.”

I emailed David York at Stringjoy who echoed exactly what you said:More labor goes into making flats. Less flats are sold so manufactures lose economy of scale. The cynical reason they cost more? They last so much longer the string makers need to make more up front because they know they won’t see another sale for a while. My experience shows that I save money in the long run buying expensive flats. I burn through rounds on most of my basses, while my p bass sits there and says, “nah, I’m good.”