From my home (according to Google Maps) it's 50 minutes so FOR ME Orlando is still the better place since everything else is there (Restaurant Row, Trader Joes, Whole Foods, Outlet Malls etc.). Of course YMMV. Takes us 1:05 so it's worth the extra 15 minutes for our once every 5-6 week trip. The Villages is so big it makes a large difference exactly where you live.
You'll NEVER see a Costco in The Villages. That the same "my hairdresser's, Uncle's Brother's dog haircutter's told me story" has been around for years. MAYBE Ocala IMO. I'l bet Costco has no desire to deal with "Villages People."