You know how, as you use larger and larger hulls, the components take up slightly more space?
Autodesigned ships aren't affected by that. All their components take up as much space as they would on a self-designed tiny ship.
That may be an explanation, since the bug mostly happens to bigger hulls.
You should stick to the auto-designed ships since I think the same bugs affect the AI and thus they would have much more powerful ships than you if you design your own.
Are you sure about that? i never saw the ai use overpowered designs. but they start with an minutarization bonus on higher difficult levels.