Polar Star
63m Motor Yacht | Lürssen
This 63m Lürssen explorer gained a 60m² carbon-fibre hardtop bimini and a full suite of upper-deck furniture, transforming the sun deck into the social heart of the yacht.
The Brief
BMComposites was commissioned to engineer, build and install a 60m² carbon fibre hardtop bimini for the upper deck of Polar Star, a 63m Lürssen explorer yacht.
At 17m above the waterline, building the structure in aluminium would have compromised the yacht’s stability, making lightweight carbon fibre the only practical option. The hardtop also needed to house two electrically operated sliding sunroofs.
The scope grew to include the dining area and bar furniture beneath the hardtop, a separate service bar to the side, and a jacuzzi with sunbeds on the deck below.
The Approach
BMComposites coordinated inputs from the yacht’s original designers, FM Architettura d’Interni, together with Espen Oeino and Azure naval architects, engineering every unit for composite manufacture. 3D scans of the yacht’s mast were imported into the 3D CAD master model to ensure a precise interface with the new parts, while the mechanisms for the two electrically operated sunroofs were developed and specified in detail within the same model.
Large-scale female tooling was cut directly from the 3D CAD data to stay faithful to the original design intent. The hardtop was manufactured in two halves at BMComposites’ facility in Mallorca, then shipped to MB92 in Barcelona for assembly, with the furniture following shortly after for final assembly on site.
The jacuzzi, sized for eight people, featured glass panel frontage and underwater lighting, while the two large sunpads either side were manufactured at BMComposites’ Palma facility and shipped to Barcelona for installation during the yacht’s extensive refit at MB92.
The Result
Thanks to dedicated project management across every stage of manufacture and installation, BMComposites’ install team completed the hardtop on board in two days, with no hot works required and minimal disruption to other work on the upper deck.
The service bar and jacuzzi followed the same approach, bonded onto the deck in an operation that also lasted two days. With new dining, sunbed and bar areas and uninterrupted views, the sun deck was transformed into the yacht’s social hub.
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From refit to bespoke composite structures, our project management team is ready to talk through what’s next.