by BMComposites | Jan 1, 2025
64m Sailing Yacht | Holland Jachtbouw
A 64m Holland Jachtbouw schooner outfitted with three large carbon-fibre deck hatches, engineered from full 3D scans for a flawless, rapid installation.
Athos called upon BMComposites to engineer, manufacture and install 3 large carbon-fibre deck hatches as part of its award-winning refit at Huisfit in 2022.
The deck hatches measuring over 4.5m in length replaced the existing aluminium hatches which, due to their size and weight, were overloading the hardware, failing to seal properly and were proving difficult to operate.
Prior to the yacht’s departure, BMComposites fully 3D-scanned the existing deck apertures including the existing scupper systems and mating sealing features.
The scan data was later used as a reference when re-modelling the new hatches using 3D CAD packages. As well as the hatches themselves, a new custom-designed hardware package was designed and manufactured.
This included multiple closing dogs with a central locking system and heavy-duty panto-graphing hinges.
Design and manufacture was carried out under the watchful eye of the Bureau Veritas Classification Society, which was included in the BMComposites end-to-end project management role.
After manufacture and painting in its facility in Palma, the hatches were shipped to Huisfit and mounted on board by the BMComposites install team.
Due to the extensive use of 3D scanning, the hatches fitted the existing apertures perfectly and were installed rapidly with minimal impact on other works on board.
Athos went on to win the coveted ‘Best Refitted Yacht’ award at the World Superyacht Awards 2023.
by BMComposites | Jun 12, 2024
40m Sailing Yacht | Wally
A striking 40m Wally fitted with fully custom carbon-fibre helm consoles, combining precision engineering with a sculptural, clear-coated finish.
BMComposites was called upon to design and manufacture new helm consoles for S/Y Black Sails, the iconic 39m Wally superyacht.
The visually-striking design and prominent positioning on board called for the precise manufacturing of the components, which were finished in a clear coating to show off the meticulous carbon fibre construction.
The design was split into two separate modules – the sleek helm pedestal, featuring a minimal amount of engine and thruster controls and a separate switch panel of hydraulic and sail control buttons, which pivoted out of the yacht’s side combings by means of a custom-designed soft-eject closing mechanism.
The helms also featured a back-lit trim line running around the periphery of the pedestals, which BMComposites achieved by developing innovative techniques to inlay laser wire during the manufacturing process.
by BMComposites | Jun 12, 2024
39m J Class Sailing Yacht | Camper & Nicholsons
This 90-year-old racing legend received a full composite deck lining system, replacing the original plywood subdeck with a lighter, moisture-resistant foundation.
In the on-going search for weight reduction within this class of racing classics, Velsheda approached BMComposites to replace the old plywood subdeck with its composite deck lining system. This is not only lightweight, but durable and also resistant to moisture ingress.
All of the several hundred deck fittings were firstly removed and meticulously logged for later re-installation.
The old deck and subdeck were removed and the aluminium deck prepared in advance of BMComposites laying lightweight SAN foam core panels across the entire deck, carefully ensuring that the original deck levels were maintained.
Each deck fitting location required a solid composite insert to be accurately cut and imbedded in the foam core.
Finally, the whole assembly was encapsulated with glass fibre to seal the deck against moisture ingress and provide a solid, even foundation for the teak deck installation.
The BMComposites install team worked closely with the Vesheda crew, paint and teak decking contractors from start to final re-install of deck fittings in a phased process, which allowed the most time efficient schedule for the deck refit.
Velsheda was launched on schedule shortly after her 90th birthday and went on to compete in the 2023 summer racing season.
