I completed the game with the Institute questline and I am now the Director of the Institute. I have read a lot of the stuff on terminals, spoken with everyone in the Institute and I still have a lot of questions about the place.
Why tell me the Director's suite is now mine and the store is now stocked with new items? The Directors suite doesn't upgrade in any way and doesn't even have a bed I can sleep in. The store items are exactly what they were before. I am told that I am the director and there will be meetings to set new policy, but that never happens either.
Why does the Institute make synths? Why make them look, act and think like humans? I can understand that the scientists wanted free labor so they could do their science stuff, but they could have just build a bunch of Mr. Handy or keep them as Gen 1. They go to a lot of effort to make them look and act human. They go through a lot of effort to program them to have personality and ability to think like humans. Then they seem genuinely shocked then they think for themselves.
Why does the Institute kidnap people and replace them? Where do the replaced people go? At one point the story had me thinking that they never actually did replace them. That those people always were synths who malfunctioned, but it becomes clear that they really are replacing people. At one point I had a random encounter with two identical people both claiming the other was a synth trying to replace him. If the whole deal is just obsessive information gathering, who at the Institute is running that program and where is that division located?
Why are there thousands of synths roaming around various locations in the wasteland? Through discussions with "Father" and others they give an impression of, "we just want to be left alone and do our research, but some synths escape." So I can see why they have the SRB coursers to track down those that escaped, but that does not explain why all of the Gen 1 and Gen 2 are out there. I followed the Railroad questline far enough to learn that the only escapes were the result of a teenage Institute boy doing it as a prank.
Why is the Institute mass producing Gen 3? Where are they going? What are they doing? The robotics lab produces a Gen 3 about once every minute, 24 hours a day, 7 days a week. Then they disappear into a hole in the wall.
Who made the decision to kidnap Shaun? "Father" explains that they wanted to make human synths and needed non-corrupted DNA. This seems to me an extreme measure for mere scientific curiosity and wanting their janitors to seem more lifelike. Kellogg was nearly immortal with his implants, so perhaps the people who made this decision and gave Kellogg his orders have similar implants and are still lurking around.
I would love to get some clarification on these questions if anyone came across any in game info that I missed or misinterpreted. I would also enjoy reading pure speculation.