Moved to avoid excessive topic drift ...
Are you sure about the figures for Aluminum?
I read that for (water) ship hulls, the aluminum plating needed to replace a steel hull would be 1.5 times as thick (so a 1 cm steel plate would need to be 1.5 cm of aluminum plate to achieve the same strength) but that the total weight of the aluminum hull would be half the weight of the steel hull (if the 1 cm steel hull weighed 1000 kg, then the 1.5 cm aluminum hull would weigh 500 kg).
In contrast, your values indicate that an aluminum craft would be heavier than an equivalent steel craft (64 vs 40), which seems contrary to the automobile industry, modern warships, APCs, and the Apollo rockets/space shuttle which all selected aluminum over steel to save weight.
Actually, it says (in MT) that it requires Striker/MT AV40 for micrometoroid and radiation protection. Even in Aluminum, that's still going to be a significant chunk of mass - 33cm basic steel equivalent - 66cm of aluminum at .8x the mass of steel is about 1.6x the mass of steel, and twice the volume. (BSD is listed as 14x the strength, but 15x the density, so 15/14 the overall mass.
You want lighter spacecraft? You reduce the armor ratings required. (Disposables like current launchers only need AV8... 2cm equivalent..
And there's the error in the design system. It is, however, consistent in all editions...
The masses of the equipment are reasonable in MT and TNE, and match closely with those of other design systems and with density calcs I've done back of the envelope on autmobiles, busses, and trains (done back in the 90's).
So the only thing which is unrealistic is the armor required. A scout courier, for example, has a base armor mass for 1cm of 40Mg. Aluminum hull for the same strength would be 64Mg. Times thickness. BSD would be 15/14 (about x1.07).
Are you sure about the figures for Aluminum?
I read that for (water) ship hulls, the aluminum plating needed to replace a steel hull would be 1.5 times as thick (so a 1 cm steel plate would need to be 1.5 cm of aluminum plate to achieve the same strength) but that the total weight of the aluminum hull would be half the weight of the steel hull (if the 1 cm steel hull weighed 1000 kg, then the 1.5 cm aluminum hull would weigh 500 kg).
In contrast, your values indicate that an aluminum craft would be heavier than an equivalent steel craft (64 vs 40), which seems contrary to the automobile industry, modern warships, APCs, and the Apollo rockets/space shuttle which all selected aluminum over steel to save weight.
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