If by "sizeable amount" you mean "more than zero" nope, I have not gotten a sizeable amount of anything from anyone since the BM1384 purchase end of June.
40GH would probably take more than 2A of 5V. Probably take 2.5V at that point, since the chip would be drawing 10.5W by itself plus conversion losses and controls. I'd estimate 12W into the stick at 40GH, which my base Compac design will handle.
I could buy an S7 and part it out, but the chips would then cost a little over three times what I paid for my BM1384 stock. End cost for the stick would be more like $30-35 than $25 and it'd take about seven S7 to prototype and run out a full 1000-stick batch. Technically possible but probably stupid.
Sounds like a expensive R/D if you have to use the unit itself. I keep hoping someone will release a chip and make competition and they will sell you a batch.
I think it might be a while but I think Innosilicon is a likely one to sell chips, unless BW and LKETC take all they can produce. Would be nice of BM to sell them to you. You should push you can help them sell R1's if they sell chips to you and make your product supported on it. Can't imagine anyone not wanting one if for 25 or a tad more you could push 25 to 40 GH of extra hash from R1.