I think you are missing the application for an Open gate array.
It is not really for you and your company. You don't have any particular interest in the open part, and thus you and your company don't fit the demographic of the sort of user we would want. We don't need your money. I can do the first runs of this using Mosis and its ilk for chump change, and go from there.
It simply doesn't matter if it's 32 nm or 15 nm or 50 nm. What matters is that the user can completely understand the bitstream and produce their own tools for it. We have no shortage of users who want that.
It doesn't matter if it is on the leading edge in terms of cost, speed, power, thermal efficiency, or size. It matters that it's open.
And maybe we can do something that you can't do with any integrated circuit available to you, which is verify from first principles that the manufactured device is without deliberately hidden security back-doors. Because we don't have intellectual property to hide and thus we don't mind producing it in a way that would make it capable of being examined.
So, I am not particularly worried about what foundry I'll use and whether I can compete on the same playing field as Xylinx and Altera. I have my own playing field, with radically different rules from the ones they are using. I have my own customers to satisfy.