by BMComposites | Jul 8, 2026
73m Motor Yacht | Lürssen
BMComposites engineered and installed a new 140m² carbon fibre roof structure for this 73m Lürssen, transforming her upper deck into an enclosed Sky Lounge.
BMComposites was commissioned to engineer, build and install a new composite roof structure for the upper deck of Coral Ocean, a 73m motor yacht built by Lürssen and designed by Bannenberg & Rowell. At 30 years old, the yacht was undergoing a significant refit, and the brief called for a 140m² structure to replace an existing satellite dome technical area, creating an entirely new enclosed space for entertaining and dining.
The new roof needed to house two electrically operated sliding sunroofs alongside integrated HVAC and AV systems, all within a lightweight carbon fibre structure suited to the yacht’s upper deck. The scope also included the manufacture and installation of a new 3.8m navigation equipment mast, fitted directly onto the roof structure.
To manage the many, often competing inputs on a project of this scale, BMComposites commissioned the Palma-based design house 3D Tech to bring together requirements from the service integration teams, composite engineers Gurit, and H2 Yacht Design, who drew the lines for the new Sky Lounge. Every feature and detail was captured in a single, comprehensive 3D CAD model, which stayed the primary reference through tooling, manufacture and installation.
The roof structure and mast were manufactured off-site in three main sections, then delivered to the yard for assembly and installation, with BMComposites project managers overseeing the process throughout. Building the components in composite from CNC-machined female tooling meant far less fairing than traditional aluminium construction would have required, a real advantage in a weight-sensitive area of the yacht.
Early 3D scanning of the deck also ensured an engineered fit for the large components, allowing the full roof to be installed in just two days with no hot works required on board.
Working closely with the captain, project management team, designers, engineers and subcontractors, BMComposites managed the process from initial briefing through to final commissioning. The Sky Lounge refit was described as the “jewel” of Coral Ocean’s €35m refit programme, and was recognised with a Judge’s Special Award at the Boat International World Superyacht Awards in 2023.
From refit to bespoke composite structures, our project management team is ready to talk through what’s next.
by BMComposites | Feb 12, 2026
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.
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.
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.
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.
From refit to bespoke composite structures, our project management team is ready to talk through what’s next.
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 ongoing search for weight reduction within her class of racing classics, Velsheda approached BMComposites to replace her original plywood subdeck with a composite deck lining system: lighter than plywood, but also more durable and resistant to moisture ingress.
The project began with the careful removal of several hundred deck fittings, each logged for later reinstallation. Once the old deck and subdeck were removed, the aluminium deck was prepared ahead of laying lightweight SAN foam core panels across the entire deck, with the original deck levels carefully maintained throughout.
Every deck fitting location required a solid composite insert, accurately cut and embedded into the foam core to take the load. The whole assembly was then encapsulated in glass fibre to seal the deck against moisture ingress and provide an even foundation for the teak deck installation to follow.
BMComposites’ install team worked closely with Velsheda’s crew and her paint and teak decking contractors, from initial deck removal through to the final reinstallation of deck fittings, in a phased process designed for the most time-efficient refit schedule. Velsheda was relaunched on schedule shortly after her 90th birthday and went on to compete in the 2023 summer racing season.
