A Faster Approach to Yacht Component Development

At BMComposites, 3D printing is fully embedded within our design and manufacturing process. Working alongside high-precision 3D scanning and CAD-integrated development, it allows us to move quickly from concept to physical part quickly, accurately, and with full engineering oversight.

This is particularly valuable in two key scenarios:

Rapid prototyping

When developing new components, 3D printing allows designs to be tested, adjusted, and refined before committing to full manufacture. This reduces uncertainty and ensures the final part performs exactly as required.

Rapid legacy component replacement

For older yachts or discontinued systems, sourcing original parts is often simply not possible. Using 3D scanning and reverse engineering, we recreate components with precision-fit accuracy — no original drawings required, no reliance on suppliers who no longer exist.

Cost-efficient production for new components

For new, small-scale components where speed and cost efficiency are priorities, 3D printing offers a practical alternative to traditional manufacturing routes, without sacrificing quality or fit.

This approach supports ongoing maintenance and upgrades without compromising timelines.

Practical Applications On Board

 3D printing is particularly effective for low-volume, custom, or hard-to-source components. Typical applications include:

• Starlink Atenna Supports

• Modified Valve System

• Ventilation System Elements

• Custom Handles and Fittings

• Crew Interface Components

• Water Inlet Parts

• Covers, housings, and small structural details

These are not afterthoughts, they are often critical components that hold up a project when they cannot be sourced. Having the capability to produce them in-house, to exact specification, can change the dynamic entirely.

Precision Fit Through Integrated Engineering

What sets us apart from standalone 3D printing services is the engineering context around it.

Using high-accuracy 3D scanning, we capture existing geometries and onboard interfaces in precise digital detail, creating a reliable reference before a single line of CAD is drawn. Components are then developed and validated through printed prototypes before final production, ensuring engineered fit and seamless installation.

The result is predictable execution and seamless installation, with no costly adjustments once work has begun on board.

>  Interested in 3D scanning? Learn more

Supporting Efficient Refit Timelines

Because 3D printing is handled entirely in-house, there are no external suppliers to chase and no lead times to manage around. This allows components to be developed and produced within tight refit schedules, supporting better coordination across the project.

It also enables early-stage validation, meaning potential issues can be identified and resolved before installation, reducing disruption on board.

As part of a fully integrated workflow that includes 3D scanning, CAD development, CNC tooling, and composite manufacturing, 3D printing plays a key role in accelerating decision-making and improving overall project efficiency.

A Practical Tool Within a Wider Engineering Process

3D printing is most effective when used as part of a broader engineering process. It sits within a complete engineering capability that supports:

• Faster concept validation

• Reliable replication of legacy parts

• Improved fit and installation accuracy

• Cost-efficient low-volume production

For captains and yacht managers, this means faster solutions, reduced risk, and minimal disruption — from the first scan to the final installation.

The 4th BMComposites Trophy

BMComposites is pleased to announce the 4th edition of the BMComposites Trophy, taking place in Palma Bay and organised by Real Club Náutico de Palma (RCNP).

Now firmly established in the Mallorca sailing calendar, the regatta brings together competitive fleets in the OK Dinghy and Snipe classes, welcoming both local talent and international sailors to one of the Mediterranean’s most celebrated sailing destinations.

A Strong International Fleet

This year’s fleet is one of the strongest yet. Among the competitors are five-time OK Dinghy World Champion Nick Craig (UK) and Andy Davis (UK), currently ranked No.1 in the OK Dinghy world rankings, two names that need no introduction in competitive sailing circles. Their presence speaks to the growing reputation of the event and the quality of racing it attracts.

Photos: Nick Craig (UK), Andy Davis (UK), Mark Branagh (UK). Credits to Robert Deaves UK / RCNP / Laura G. Guerra

A Special Debut

The 4th edition also marks a significant moment for BMComposites. A newly designed BMComposites OK Dinghy will make its racing debut at this year’s regatta, sailed by Nick Craig himself, a fitting first outing for a boat built for performance.

About the Event

As title sponsor, BMComposites is delighted to support an event that connects the international sailing community with Palma’s vibrant marine scene. The link between performance sailing and advanced composite engineering is a natural one, and the BMComposites Trophy is a celebration of both.

“We are thrilled with the increasing popularity of the BMComposites Trophy regatta. Now in its fourth year, we have the largest turnout to date, with over 40 entries, attracting a line-up of top-level sailors from both the OK and Snipe classes.

BMComposites will also be showcasing our own designed prototype OK Dinghy, which will be sailed by previous world champion Nick Craig. I would like to thank the organisers at RCNP, extend a warm welcome to everyone, and hope we have great conditions for this upcoming event.”  – Mark Branagh, CEO, BMComposites

At BMComposites, we design and deliver advanced composite structures with purpose and for performance optimisation.

Specialising in superyacht roof structures, hardtops, and biminis, we work with lightweight marine-grade composite to create corrosion-resistant and installation-efficient solutions.

Whether working with yacht managers, captains, or international shipyards, our goal is the same: every structure must perform flawlessly at sea – not just look the part, but operate with precision and reliability.

Our composite roof structures are engineered systems, not just covers. They are designed to:

• Provide reliable sea and sun protection
• Withstand structural load-bearing
• Integrate seamlessly with AV, lighting, retractable panels, and secondary systems

Constructed from carbon fibre and epoxy laminates, our structures are:

We design, manage, and deliver the entire scope of system integration in-house. This ensures alignment between structure and systems, simplifying refits and avoiding post-installation adaptation.

Our integrated solutions include:

• Custom-fitted glass windscreens and Strataglas™ clear panels
• Electrically actuated sunshades and opening roof panels
• Solar panels integration within the composite structure
• Lighting and AV systems, with cable routing pre-planned
• Interfaces for HVAC and fire-fighting systems
• Pre-mounted, removable headliners for easy service access
• Load-bearing integration for communication equipment and radar masts

Benefit for clients: fewer delays, fewer unknowns, and a single point of responsibility.

• 140m² carbon fibre roof with twin sliding sunroofs & navigation mast
• Installed in < 48 hours, no hot works required
• Recognised for speed and complexity of execution

→  Superyacht Times: Coral Ocean Reborn

Photo Credit: Coral Ocean, Jeff Brown, Ahoy Club

• 60m² composite hardtop with lighting, sunroofs, Jacuzzi integration, and bar framing
• Structurally bonded, installed in Barcelona with no modification

→  BOAT International: Polar Star Refit

Photo Credit: Polar Star, Stuart Pearce

• Three laminated biminis with AV & lighting integration
  
• Delivered pre-finished, shaped directly from tooling — zero onsite cutting

→  Superyacht Times: M5 Flybridge Refit

Photo Credit: M5

• Solar-integrated bimini for long-range, self-sufficient cruising
• Aerodynamic form to preserve airflow and durability

→  Composites World: Solar-Powered Hardtop Bimini

Photo Credit: Interpid

The OK Dinghy European Championships 2025 in northern Germany were nothing short of challenging. The Baltic Sea tested every sailor with a mix of conditions—ideal for pushing skills to the limit.

Representing Spain and Real Club Náutico de Palma, our team put up a strong fight. As BMC Director Mark Branagh noted:

“We had some great upwind legs in Races One and Three, but we need to close the gap downwind against the Danes, Germans, and British.”

Now, Mark’s OK Dinghy is back at our BMComposites workshop for race tuning and optimisation ahead of the World Championships at Lake Garda—where over 200 entries are expected!

Congrats to Charlie Cumbley on a well-deserved win!

Small refinements can mean big results. Whether you’re preparing for a regatta or planning an off season upgrade, our expertise can help you gain the edge. Our team specializes in:

✔ Race tuning & rig optimisation
✔ Composite repairs & upgrades
✔ Custom hardware solutions

At BMComposites, we help sailors, boat owners, and teams get the most out of their equipment through innovation, craftsmanship, and precision engineering. From high-performance composite solutions to custom refit projects, our mission is to help you go further, faster.

Your performance is our passion. Let’s make it happen.

When SuperYacht Times featured BMComposites for our work on the iconic 73m Coral Ocean and the legendary M5 sailing yacht, it was a proud moment, but also a chance to talk about something much bigger: 

How composite materials are redefining the future of superyacht refits. 

Read the full Superyacht Times article here.

From our base in Palma de Mallorca, we’ve spent two decades pioneering composite solutions for the most complex projects in the superyacht industry. What makes composites so powerful? Efficiency. Precision. And a total rethink of what’s possible. 

In a world dominated by aluminium and steel, composites give refit projects a critical edge. And when it comes to superyacht refits, composite materials are no longer a luxury; they are the future, here is why:

• Significant weight reduction (key for stability-sensitive structures like hardtops and biminis)
• Faster installation (our Coral Ocean structure went on in two days – no hotworks needed)
• Less disruption to other trades during the refit cycle
• Better finish with fewer fairing and painting cycles

We build large, complex structures off-site in our purpose-built Son Moro workshop while other teams carry on work at the yard, that way we are minimizing downtime and maximizing precision. For busy charter yachts, that means earning while we’re engineering. 

For Coral Ocean, we engineered a new 140m² sky lounge from composite foam-cored panels with dual electric sunroofs and a sleek nav mast. This Lürssen superyacht received a major deck transformation that became the “jewel” of the refit based on the Judges’ Special Award at the 2023 Boat International World Superyacht Awards.

For M5, the world’s largest single-masted sailing yacht, we delivered three custom carbon-fibre hardtops and helm upgrades, balancing cutting-edge AV and lighting integration with Adriana Monk’s refined design aesthetic. 

Read more about:

Coral Ocean and the new Sky Lounge

M5 carbon-fibre Flybridge Refit

We combine 3D scanning, CAD modeling, and CNC-machined tooling to deliver millimetre-perfect results that are structurally sound and visually stunning. It’s not just about construction, but also about translating vision into reality with efficiency and without compromise.

Find out more about 3D Scanning Capabilities

Composites aren’t just a material choice, we see them as a design philosophy. They unlock lighter, smarter, more sustainable builds with faster turnarounds and less compromise. And for refits, that’s gold.

Whether you’re a superyacht captain, project manager, or shipyard, BMComposites offers a seamless refit solution from concept to completion. Designed in Mallorca, delivered anywhere.

SuperYacht Times – Refit: BM Composites and the rise of advanced materials: https://www.superyachttimes.com/yacht-news/bm-composites-palma-yacht-refit-shipyard

Boat International – The winners of the World Superyacht Awards 2023: https://www.boatinternational.com/luxury-yacht-events/world-superyacht-awards/winners-2023