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That being said, I'm not entirely sure how the developers, or a modder for that matter, might make this idea a reality.
Under the current system that is already in place, the only possible way that this might work would be to create an upgrade system that you could then use on each individual block to 'upgrade' it. The one main problem with this system would be that you would have to re-weld each block to upgrade it, and depending on how your ship was constructed, you may not be able to actually get to some blocks to weld/upgrade them. This would inherently create weak spots in the construction of your ship.
What I'd do is install the Nanobot Build and Repair mod. When you want to upgrade a section of armor, grind away a light armor block, put down just the frame of the heavy armor, and let the mod build up the rest.
But.... Changing to heavy armor means there's more mass, so you need more thrust, so changing from light armor to heavy armor frequently means a complete redesign because you have to put more thrusters on it.
Now getting past the obvious differences of light vs heavy that people repeatedly keep pointing out...
Being able to upgrade ships without having to tear them apart would be wonderful. The amount of time saved from upgrading instead of tearing down to replace? Hours in many cases.
A whole host of things "would be difficult to implement" but Keen managed to put them in.
As for the idea of upgrading, I doubt it would work due to the sandbox nature of the game, the idea of at least a block swap might work in both creative and survival but might still be a pain to implement.
That said the choice between light and heavy I find is a matter of where to use the latter. Heavy is good if building a hidden underground base for that part which is exposed, generally this lowers cost while still giving good defence, space stations also benefit from heavy armour if you have no plans to relocate them.
For ships, I largely avoid it outside of maybe a hidden battle bridge box/tomb due to both massively making ships harder to accelerate and turn and the cost, add the block deformation issues that can rend them useless anyway and now with piercing ammo with warfare 2 pack, spaced light armour remains as I see it king.
i myself typically use heavy as like a skeletal structure to support and hold together important components of the ship. i rarely go all in on one or the other. its part of the design aspect of things to balance out ship design and its intended use. i'd never build a miner with heavy armor block for example (or really any armor. if i can avoid it. less mass = more maneuverability), for a fighter, i'd have some heavy covering important components and protecting the cockpit to some degree. but the ship wouldnt be 100% heavy block.
then there is the boarding party vessel, where its designed to slam into another ship to inflict damage and carry a crew in to take it over, THAT i'd probably build out of pure heavy block for the mass and the armor to protect the crew inside, but this is a purely PvP thought design, i've never actually made this.
all in all i wouldnt be opposed to a medium armor block, but i could also live without it. what i'd REALLY like is improved window blocks so i can build a custom cockpit more easily... soo many window blocks that simply do not want to connect to certain ones... that and maybe a smaller airtight door of some kind for small blocks. a 5x5x1 was a bit much for somethin i was tryng to make look good, but a 3x3x1 would have been perfect.
and yes i know mods exist, but i like to create things that someone can simply pull from the workshop and it just works.
On the other hand, it feels like our issues are the same; the difference being that whereas you finished your ship using light armour, I just waited until I had enough resources to put on some proper armour.
We both bit off more than we could chew... and this is basically what happens when we don't think things through.
I got my ship cut in half because a cargo container popped, but that only happened because I let items accumulate in unarmoured containers.
You could've built a "patch" of light armour on your ship and shot it a couple of times to get an idea of how much protection you'd get out of light armour.
Moral of the story is to know your limits, to build up your industrial strength before undertaking these enormous projects (at least when in survival mode), and to think a few steps ahead when making changes to the construction plan.
Heavy armor is okay for skirmishes... against lightly armored opposition.
Double heavy armor: it's the minimum I'd recommend if you want a chance of surviving against other players on a public server or battling Factorum ships. Your double armor can consist of one layer of heavy and another layer of blast door armor. Having a non-deforming layer can be advantageous. If you're going to stand and fight, double wrap it.