Last November I spent a fascinating few days at HP's printer research labs in San Diego and Boise. I couldn't fit as many details as I wanted about the various testing chambers - variously lined with copper or anechoic cones, subjected to extreme heat, light or humidity, blasted with interference and static or filled with forensic equiment to rival CSI - into my latest piece for
FT Digital Business. But
I do explain the rice grains and the Arizona road dust... Printable version here
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marypcb
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That said however... one thing I U-turned on was always buy HP printer carts (as you said). Yes they are frigging expensive but they generally do a much better job than the ones half price in PC World.
Buying a new (laser?)printer at some point has made me rethink the costing of printers and take less notice of the price of the actual hardware beyond a certain ('does it do what I need now and in say a year's time?') level and look more carefully at the quality of the refills... If it has taken me a while to grok then it will take Mr and Ms PC World a lot longer to look beyond the price sticker of the printer...
I still think HP Inkjet refills for my old PSC750 are hellish expensive though -- shame its so good at what it does.