Well, the crash is probably due to obsolete ship designs. If you play a game without obsoleting any ships or overwriting any existing ship designs, you should be able to avoid this crash. You can still save your ship designs, just make sure that you pick unique names for them.
Not the case. I have only ever made one ship design period. The one I made has a unique name.
The bug happens after a certain lenght of time. I can save and load fine early in a game.