Navigating the Future of Shipbuilding: Leveraging AI to Overcome Systemic Delays

by Troy Bouffard (Guest Post) – The shipbuilding scene in the U.S. has been struggling for decades, especially when it comes to military vessels. As the 1980s, projects have consistently run over budget and behind schedule. Recent years have shown that this trend is not just a fluke; it’s a systemic issue affecting all types of ships.

Take the Gerald R. Ford-class aircraft carrier as an example—this program has faced years of delays and ballooning costs due to challenges with integrating new technologies. Submarine programs like the Virginia-class and Columbia-class are no different, grappling with setbacks from supply chain issues and workforce shortages.

The coast Guard’s Polar Security Cutter project also highlights these struggles, especially given its complex design requirements for Arctic operations combined with limited experience in icebreaker construction within U.S. shipyards.

Even simpler vessels like the John Lewis-class fleet replenishment oilers haven’t escaped unscathed; they too have seen their timelines slip significantly. On average, initial estimates for delivery can stretch by 30-60%, while costs can soar by 25% or even double original projections.

These delays are more then just numbers—they impact national security capabilities, especially concerning critical assets like Columbia-class submarines that play a vital role in strategic deterrence.A recent Congressional report shed light on these persistent issues within shipbuilding capacity and offered some insights into potential solutions. Building modern military ships is no small feat—it involves thousands of workers coordinating millions of parts over several years across various production stages: design, material procurement, hull construction, outfitting, systems integration, testing/commissioning, and sea trials.

As a notable example, constructing an aircraft carrier from the Gerald R. Ford class requires around 47 thousand tons of steel and typically takes five to seven years under ideal conditions! Each phase presents its own set of challenges that can lead to significant delays if