Hi,
The problem seems to be that when you upgrade a ship and remove or downgrade a component, the new design still has the tech requirement for the missing component. I ran into this problem because I decided to make "Template" versions of my favorite ships by removing all the components and leaving just hull and extras. However, when I started a new game the Templates were unavailable in the shipyard and in the tech tree they had the same requirements as the model I had used to make the template.
I did some testing to verify what I was seeing.
Test1 was a cargo hull with nothing but extras. It showed up with no tech requirements and could be immediately built in a new game.
Test2 was upgraded from Test1 and included a SensorsMkIII and a General Life Support. The tech requirement showed as expected.
Test3 was upgraded from Test2 and removed the sensors and life support unit to make the ship identical to Test1. However I couldn't build it in a new game and the tech tree still listed the missing components as required.
Test4 was also upgraded from Test2 and just replaced the SensorsMkIII with a SensorsMkII. The tech tree lists both MkII and MkIII sensors as required.
Apologies if this issue has already been posted. Thanks.