For example: If I start with an empty ship (0.2 conventional armor and 1 fighter crew quarter) the total wheight of the ship is 12t, 1 Crewmember, 3 spare barth. So far so good. Now, if I add lets say a bridge which, according to the list adds 50t of wheight (or 1 HS) and has a demand of 5 Crew, the wheight goes up to 92t (due to armor increase to 0.9) but the Crew count is still 1 and three spare barth. Am I misinterpreting the "demand list" for the bridge?!?
Ok I have a little time on my hand.
1. I don't think that you can create a crew less class, even if you create silly design with total of 0 crew requirement it still say 1.
2. what is your Deployment Time and what type of Armor you have?
Deployment Time time effect how much "life support" you'll need per crew member. The formula is:
HS allocated to Crew = [Crew Breth * CubeRoot(Deployment Time) / 50 ] Rounded up to nearest multiplier of 0.2 (size of tiny quarter)
Which should be equal to Accom_HS_avail. Note, there are couple of special cases for any ship with Deployment time of less than 0.5 or 0.1 month. This is covered in detail in the 6.0 version changelog.
As for armor, its:
Armor_HS = Armor_Surface_Area / 4 / Armor_Tech_ratio // do per layer.
When Armor_Surface_Area is calculated from total ship component size converted volume to surface.
EDIT:
On an unlrelated note, can someone please post a screenshot of Class Design window, from v7.1 in full height.