U.S. Navy Struggles to Meet Frigate Production Goals Due to Shipyard Capacity Constraints

The U.S. Navy's ambitious plan to build a fleet of 66 frigates as part of its Golden Fleet initiative is facing significant challenges due to insufficient shipbuilding capacity in existing facilities. The current goal requires the construction and delivery of more than three frigates per year by 2037, a pace that cannot be sustained with just one shipyard. This necessitates the involvement of two shipyards to meet the Navy's objectives.

The plan initially aimed for two shipyards: Marinette in Wisconsin and Ingalls in Mississippi. The first phase involves completing two Constellation-class frigates at Marinette by 2031, while a modified U.S. Coast Guard National Security Cutter will be produced at Ingalls during the same period. However, the Navy's timeline for achieving these goals has been delayed due to various complications.

Since the program's inception in 2019, no frigates have been built, highlighting ongoing design uncertainties and delays. The Constellation-class frigate program was canceled by then-Secretary of the Navy Phelan in November 2025 because it was deemed too costly relative to its capabilities—80% the cost of a destroyer but providing only 60% of its functionality. This cancellation led to a pivot towards repurposing National Security Cutters, which have already demonstrated their viability with ten previously delivered units.

The decision to use modified National Security Cutters presents both advantages and challenges. While HII's Ingalls shipyard has the potential to ramp up production quickly due to existing infrastructure and workforce capabilities, significant modifications will be required before these cutters can meet Navy standards for surface combatant vessels. This includes enhancements such as modest air-defense systems, torpedo magazines, additional fuel storage, and crew accommodations.

Meanwhile, Marinette Marine, which had invested heavily in the Constellation program, has laid off many of its expanded workforce following the cancellation. However, if a finalized design is achieved soon, Marinette could still deliver initial frigates faster than Ingalls can modify existing cutters. Both options currently face capacity constraints that threaten to delay the Navy's shipbuilding goals.

In response to these challenges, President Trump issued a memo in August 2026 outlining plans to increase domestic shipbuilding capacity through strategic investments and partnerships. These efforts aim to address immediate production bottlenecks while laying the groundwork for long-term growth in naval manufacturing capabilities.

The U.S. Navy's struggle with frigate production underscores broader issues within its shipbuilding industrial base, including workforce shortages, supply chain disruptions, and design complexities. Addressing these challenges will be crucial for the Navy to meet its strategic goals and maintain a competitive edge in global maritime security.