Case Studies – Polar Star

Brief

In 2015 BMComposites was commissioned to engineer, build and install a 60 square meter carbon fibre hardtop bimini for the upper deck of the 63m Lurssen explorer yacht.  At 17m above the waterline, the weight of building in aluminium was deemed unfeasible when considering the vessel stability, so building in lightweight carbon fibre was the only alternative.  The hardtop was also to feature two electrically operated sliding sunroofs.

In addition, the yacht commissioned BMComposites to build the dining area and bar furniture beneath the hardtop, a separate service bar to the side, plus a Jacuzzi with sunbeds on the deck below.

Approach

Working closely to co-ordinate inputs from a plethora of vested interests; including the designers –  FM Architettura d’Interni, the original designer of the yacht, Espen Oeino and Azure naval architects, BMComposites engineered the units for manufacturing in composites. 3D scans were taken of the yacht’s mast and imported into the 3D CAD master model to ensure a perfect interface with the parts being developed in 3D.  The mechanisms for the two electrically-opening large sunroofs were also developed in detail and specified in the CAD.

Large scale female tooling was cut directly from the 3D CAD to ensure that the designer’s original intent was realised faithfully.  The hardtop was manufactured in two halves in the BMComposites manufacturing facility in Mallorca, loaded onto a transport and shipped to MB92 in Barcelona for assembly onto the yacht.  The furniture parts followed on shortly afterwards with final assembly being carried out in Barcelona.

Final install of the hardtop on board was achieved in two days with no hot works required and minimal impact to other works going on the upper deck.  The same was true for the service bar and the Jacuzzi which, due to the prior detailed development of the parts, were installed rapidly.

The Result

Due to the dedicated project management of all stages of manufacture and install, BMComposite’s professional installation team was able to arrive on site and install the parts within days.  The use of lightweight composites in the manufacture of all hardtop and furniture components allowed the designers to make full use of the available space and completely reimagine the guest areas.  With its new dining, sunbed and bar areas and uninterrupted views, the sun deck was transformed into the social hub of the yacht.