okay, i'm officially tired of discussing this. i didn't make this thread to get flamed, i just wanted to ask a question, and i got exactly what i expected: a lot of people blindly defending the movie as "the best masterpiece EVAR BLAH BLAH !! how could you not agree with me?!?!!", mixed in with a few logical responses.
Well, I'll try and give a few respectful reasons as for why this movie may have cost so much.
1. The cast was a dream-team of Oscar caliber actors, at least 7 of whom (Bale, Caine, Ledger, Oldman, Freeman, Eckhart, Gyllenhaal) would command fairly hefty paychecks. Likewise Nolan's fee as director would probably be pretty high.
2. Location shooting cost a lot ($45 million). You argue that Nolan should have shot exteriors and simply soundstaged the rest, however one of the constant selling points for The Dark Knight in reviews has been the epic, city wide scope of the story. A lot of this is accomplished through location shooting. Just by simply having the city in the background the scope of the film is much more expansive, and Nolan was unwilling to compromise the quality of his film through a soundstage. Furthermore the trip to Hong Kong would have cost a significant amount, with transportation and filming costs.
3. While the effects are practical rather that CGI, that does not always make them cheaper. Blowing up real buildings is expensive, and even when CGI may have been the cheaper route, the costs are still high for practical effects (such as the flipping semi).
4. The CGI in this movie is a lot more extensive than you likely think, simply because it is so understated. Sure, Two-Face is an obvious point where CGI was used, but every shot of the ferries was largely CGI based (you can probably still find photos of the ferries set which consisted of the ferry entrances with green screens behind to add the rest of the ferries as well as the backgrounds). Also consider the cost of the Sonar sequences.
5. Constructing things like the new suit or the Batpod require a serious amount of money (especially with the latter).
6. As others have mentioned, the IMAX sequences were likely very expensive and cumbersome to film.
7. As others have also pointed out, Christopher Nolan also refuses to utilize a second unit. Quality over costs (which, in this case, seems to result in greater financial gain).
Anyways, that's my basic breakdown, I'm sure I missed a few things, but all in all I wouldn't say that that $180 million was used so poorly.