I'll take a stab with very broad brush stokes... fire away.... and of course it's "stihl oriented" 'cos it's what I know best...
There have been a lot of changes in saws over the past 25-35 years. The primary change is that the pro makers (not just Stihl) figured out how to make a saw for the consumer market as well as the pro market. Take the 031/32 for example - great old saw, many still running today, but it cost $350 or so 25 years ago... So in todays money, that's the cost of an MS 460. Not a lot of average consumers bought them... and it's where Stihl got labeled as expensive. Same for the 028 and 026.. and the 024 and 036. They tried to make the 024 as the consumer saw, but it really wasn't a lot different to the 026 in manufacture cost, and the same with the 034/36, and many other examples.
Part of the figuring was to partition the market and not have one part sully the good name of the other... - not all users put 6 hours a day / 200 days a year on their saws, so those users don't need or want the added cost of "pro" saw. On the other hand, the pro's demanded lighter, more powerful and more reliable saws.
Getting way from Alum and/or Magnesium casings was one change. Simplifying the manufacturing process was another. The Consumer grade saws are mainly PA66 (nylon) with the better saws using the GF form (Glass fiber filled). Pro saws use some PA66-GF, but in the parts that matter, Magnesium alloy is used.
Today's plastic is really tough. It's cheaper to manufacture than Mag, so most of the consumer saws are made from it. Combine this with simpler manufacturing, and you and up with a less expensive saws. The downside is that the consumer saws are harder (i.e. more expensive if done at a dealer) to repair than a pro level saws.
I like pro level saws, but the best sellers (quantity) are the consumer grade. The 290 (refered to as a boat-anchor by several AS members) is one of Stihl's best sellers, ditto with the MS250, and the consumers that buy them love them.. The good thing with Stihl (not a advertisement..) is that the consumer grade saws are really quite good and last well when not abused or used in a pro environment. Some other manufactures of the 80's and 90' with solid brand names went for "really cheap" consumer while trying to hold their pro position... and failed at both.
The pro grade saws today are a world ahead of the older saws (when they were all "pro grade"). Sure, an 041 FB or 051AV are great old saws, and cut real well, but heavy full-on-bone-shakers and slow reving. The next generation - 36/38/44/46 etc were better - much easier to work on, more reliable, faster cutting etc, lower vibration etc. The latest generation - the MS361 and 441 take it to the next level of vibration and reliability (441 still has to prove itself of course, but the 361 definitely has)..
O.k., that should start some arguements
opcorn: