This site might be helpful:
aurorawiki.pentarch.org
Ah. Of course there's a wiki entry. Silly me.
Thing is, when people discuss this stuff it's helpful if they explain terms we haven't seen in the thread before.
EDIT: BTW, what production facilities produce ground units an what opportunity or other costs will be incurred there?
Ground units are build by a Ground Forces Construction Complex
aurorawiki.pentarch.org
As far as costs goes, the complexes themselves take duranium and neutronium, while ground units use Vendarite which isn't used much outside of ground units.
So you're looking mostly at the opportunity costs of using construction factories to build the GFCC's (or 'training facilities' since that is easier to remember and sets it apart from other types of construction complexes) and those minerals.
But the units themselves have very little opportunity costs because vendarite is more or less inconsequential outside of this purpose. At some point if you have a lot of training facilities you may have to divert mines to get more of that stuff, true, but odds are you won't need to.
Except of course the research. Which is it's own specialty, so we're mostly talking labs.
And finally, you want troop transports capable of dropping enough tonnage of ground units quickly. Those take shipyards and (civilian) ship construction capacity. If your invasion target doesn't have a nearby body that we can use as a staging area you'll need a lot of them. 3 million tons worth of troops (minimum!) takes 3 million tons of troop transport bay and if you need to travel more than 8 hours (a standard ground combat cycle on a planet) you want to be able to drop a very large percentage of that in a single transport cycle.
So we're talking something along the lines of 20-30 100.000 ton drop racks, but it could be as many as 100 vessels.
And if you want those ships to be able to survive through STO firing at them -- thereby making killing them from space with beam weapons unnecessary - it gets more expensive due to the required layers of armor and the need to put some engines on them or create armored tugs.
That said: conquering a NPR homeworld is incredibly good for your empire. Even today, in this game, Earth is by far the most built up planet we have. No other planet even comes close. Imagine capturing a world that is 20% bigger than your original homeworld in every respect joining the empire. It's huge. Hundreds, possibly thousands of installations of more or less every type. Billions of alien pops.
And there is only one way to do that. There is no diplomatic annexation.