“Most” people can have it and there’d still be millions (tens of millions, even over 100mill) of people who don’t. Multiple states don’t even require it. That guarantees several million people right there.

I think New York is one, so well over 10mill people don’t require it. Do you seriously think most of those people are getting one anyway? Guarantee you there are millions of people without it if not tens of millions. I’d put money on it.

So back to the point, we’re talking likely 100’s of millions of dollars. That is nothing to sneeze at. The TSA is an $11bill operation based on a quick search. $500mill (~11mill people) would be 5% of their annual budget.

America only has 340 million people to begin with. Then, half the population doesn't even fly in a given year. Those that do are mostly aware of the RealID requirement and either got it whenever they last renewed their driver's license, or renewed early because their DMV kept mailing them warnings about needing to do so if they wanted to fly. Yes, most people who fly either have it, or are getting it before their next flight. Part of the $45 fee is also to incentivize people to get the RealID, as that will obviously be cheaper for them over the long run.

That's the point. It's not to make money. The primary purpose is to get people to use RealID, and to cover the costs of the extra screening for those who don't. For however much more money they take in, you need to subtract the cost of the additional staff they need to hire and pay to handle it, plus the tech systems.

Also, remember you can just use a passport instead. That hasn't changed.