Printing is just not very expensive, relative to the size of the US economy. People like the $1 note. I just don't think it's going to happen for another 2x-4x reduction in the value of the note.
Give it 15-40 years and we'll think about it again!
Of course, by then, so much of commerce will be electronic that I don't think anyone will care about what notes still circulate, other than the $100, which is used more outside the US than inside.
It's not _just_ printing though it's transport, storage and distribution then at the end of it's life span collection and destruction. In 2023 the US printed 2,397,104,000 in $1 bills alone. Doing anything at that scale is not cheap no matter how inexpensive a single unit of production is.
Give it 15-40 years and we'll think about it again!
Of course, by then, so much of commerce will be electronic that I don't think anyone will care about what notes still circulate, other than the $100, which is used more outside the US than inside.