The prototyping effort tested and refined production processes, systems, tooling, facilities and workforce skills before their wider use in the shipbuilding program. The work covered structural construction, mast manufacturing and outfitting, providing practical experience for the transition into frigate production.
Five prototype blocks — 03, 04, 05, 10 and 16 — were built using the UK Type 26 City-class frigate as the Hunter design reference. A Hunter-class frigate comprises 22 blocks, with the five prototypes selected to address technical requirements considered important to the build.
Prototype construction began in December 2020 and continued through disruption caused by the COVID-19 pandemic. The first 28-ton steel unit was manufactured in less than a year and later joined with three other units to form Block 16.
The completed Block 16 covers 452 square meters and required 45,000 production hours. BAE Systems Australia said the structure continued to serve as a test platform during later stages of the prototyping program.
A separate Mast Proof-of-Concept project ran between 2023 and 2026, involving teams in Perth, Adelaide and Melbourne. Most of the work was carried out at the Henderson shipyard, where approximately 20% of the full-scale mast was produced to test the new design.
Unlike the steel hull blocks, the mast prototype was manufactured from aluminum, which required different production techniques. The work also included precision machining of radar seats, while the Henderson team has now begun producing the mast for NUSHIP *Hunter*.
The final stage of prototyping shifted toward outfitting, covering the integration of non-structural equipment, heating, ventilation and air-conditioning systems, electrical systems and pipework. Block 16 was also used to install a representative crew accommodation space with bunks, carpeting, plumbing and furniture.
The prototyping phase ran alongside construction of NUSHIP *Hunter* as the program progressively moved into production. BAE Systems Australia said the work also provided opportunities to involve local small and medium-sized companies and develop Australian industrial capability.
With prototype activity now concluded, experience from the five blocks, mast project and outfitting work is being carried into the Hunter-class build. The program is continuing construction of the first frigate while preparing for the vessels that will follow.
