VENICE, Italy — Lights flickered in a theater on Norwegian Cruise Line’s new ship.

However, this was not part of a performance. A worker was welding on the second level, which will soon become the Aqua Theater & Club, currently under construction on the Norwegian Aqua.

YSL News was among a select group of media that observed the shipbuilding process at Fincantieri shipyard in Venice, Italy, earlier this month. The vessel is nearing completion in preparation for its launch next year.

Here’s what is involved in getting a ship ready for sailing.

Where are cruise ships made?

Most cruise ships are constructed in Europe – 98% as per the Cruise Lines International Association – at locations like Chantiers de l’Atlantique in France, Meyer Werft in Germany, and Meyer Turku in Finland.

Fincantieri, an Italian shipbuilding company, is crafting Norwegian Aqua at its Marghera shipyard, located around five miles from St. Mark’s Square. They have also produced ships such as the Discovery Princess for Princess Cruises, Rotterdam for Holland America Line, and MSC Seascape for MSC Cruises.

How long does it take to build a cruise ship?

The shipbuilding process spans several years, as explained by Patrik Dahlgren, Executive Vice President Chief Vessel Operations and Newbuild Officer at Norwegian Cruise Line Holdings.

The company is currently in the early design phase for a new ship class, with the first unit expected to be completed in 2030. This stage can commence earlier, depending on the complexity of the design. “(It) depends on how many different components you have,” he noted.

Typically, construction spans between two to three years.

Dahlgren mentioned that the work is progressing well for the Norwegian Luna, which is set to begin its journey in 2026, along with the first of two final ships in the Prima Plus Class expected to join the fleet in 2027.

Work on the Prima Class began back in 2015. “With Norwegian Prima and Norwegian Viva successfully launched in the last two years, we have gained valuable insights from our guests and crew, using that feedback to create an exceptional experience in Norwegian Aqua,” Dahlgren stated.

What is the process of building a cruise ship?

The journey begins at the conceptual stage. According to Dahlgren, this is when the line assesses successful aspects of prior ships and the industry’s overall trends.

“Before engaging with a shipyard, we establish a vision and concept for the desired outcome,” he elaborated. Norwegian Cruise Line Holdings has a dedicated internal team of 100 focusing on new designs and collaborates with an external naval architecture firm.

The architecture team, leveraging insights from Prima and Viva, works closely with the brand and executives to design Aqua, including its aesthetic details – for instance, modern cabin interiors highlighted with ocean-inspired blues – and various onboard activities. The aim was to infuse a “modern touch” while remaining true to the brand’s essence.

Dahlgren stated, “Our ultimate aim is to weave an enriching narrative through design, making each area enhance a remarkable guest experience.”

The next step involves assessing the availability of shipbuilders. “There’s significant competition among cruise lines for these slots,” he added.

Up until around 20 years ago, Dahlgren mentioned that all elements of a ship were constructed on-site, but today, these components are fabricated individually in factories.

warehouses. “It’s similar to building with Legos, where different parts come together,” he explained.

He reminisced about crews once balancing on ladders “working on the ceiling” during his early days; nowadays, components are assembled upside down, then flipped, positioned with cranes, and welded together.

“After they complete the basic structure and mechanical systems of the ship, the dry dock is flooded, allowing it to float,” he noted.

The subsequent tasks are carried out in a wet dock.

This is where “the actual work starts,” according to Dahlgren. This stage involves installing pipes, fitting air ducts, and laying down electrical wiring.

“As they work on the ship’s technical aspects, thousands of employees are involved in outfitting the vessel to realize the architects’ designs from months prior – including restaurants, lounges, bars, theaters, shops, staterooms, and more,” he shared.

Creating the intricate features common in modern cruise ships can be a significant challenge, even for skilled shipbuilders.

For example, Emanuele Truant, VP of NCL Project at Fincantieri, described the Aqua Slidecoaster—a fusion of waterslide and roller coaster—as an “engineering challenge,” during a discussion after the shipyard tour. Traditionally, ships have lighter construction at elevated sections, but this ride incorporates about 40 tons of water moving swiftly at the top of the ship.

“I wasn’t completely surprised about the slide’s plans,” Truant said. “But I expected it to be much smaller.”

Where do cruise ships source their furniture?

Norwegian’s in-house designers collaborate with external companies to develop the ship’s visual style.

A large portion of the furniture they use is custom-built, tailored to withstand the coastal conditions. Items situated outdoors, for instance, “must be exceptionally robust” to endure exposure to the elements, Dahlgren highlighted.

As for stateroom furniture, it is delivered alongside the cabins, which are built separately before being fully outfitted and incorporated into the ship.

The concluding phases usually involve rigorous testing of the ship’s systems at the yard, known as the commissioning phase, as well as at sea, referred to as sea trials. Generally, these trials occur about four months prior to the ship’s handover, allowing sufficient time for the shipyard to address any potential issues that arise.

During the Aqua shipyard tour, the vessel appeared less complete than expected for a launch set for six months later. Saws buzzed as the group moved through the decks, which displayed exposed HVAC systems and hanging cables.

However, Dahlgren stated that the ship was actually 96% complete. While it may appear differently when constructing a house, the shipbuilding process sees many behind-the-scenes elements put together first.

“From the outside, it seems like it’s going to take five years to finish, and it would if it were a land project,” he remarked. “However, the pace is entirely different in shipbuilding.”

This story was made possible through access granted to the event by Norwegian Cruise Line. YSL News retains full editorial control.