For the cheap boards, I'm thinking stm32f091cc. There's 256kb flash and 32kb RAM, and it's a small package and hopefully cheap enough. The second you add USB the price takes a bit of a hike.
It's hard to find parts with 256kB flash that are small, but not BGA.
I'll have to have a look at the castellations - it does add to the price (I think it makes the milling bits wear out more quickly so PCB makers don't like it), but if I used a thinner PCB it would help.
It's actually going to be a bit of a juggling act between making it small and bringing out enough IO. I wonder whether I could do it in a DIP style, but allow the end to be snapped off if you wanted it small but didn't want the extra IO - but then that all adds to the cost :(
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