by BMComposites | Jul 8, 2026
73m Motor Yacht | Lürssen
A classic 73m Lürssen reimagined with an entirely new 140m² composite sky lounge and roof structure, engineered for weight, comfort, and seamless system integration.
BMComposites was commissioned to engineer, build and install a new composite roof structure for the upper deck of the classic, Bannenburg & Rowell-designed motor yacht Coral Ocean (formerly Coral Island) – a 73m, 30-year-old, Lürssen. The new 140sqm roof structure would replace a sat dome technical area on the upper deck, so creating an entirely new enclosed space for entertaining, dining and parties. The roof structure would also include two large electrically-operated sliding sun roofs, plus HVAC and AV systems.
Also included in the upgrade was the manufacture and installation of a new 3.8m high navigation equipment mast atop the new roof structure.
BMComposites commissioned the Palma-based design house 3D Tech, to integrate the many and often conflicting inputs from the service integration companies, the composite engineers, Gurit and H2 Design Yacht Design who drew the lines for the new Sky Lounge. All features and details were captured in a comprehensive 3D CAD model, which became the primary reference throughout the project lifecycle from tooling, component manufacture and final installation.
The large roof structure and mast was manufactured off-site and delivered in three main parts before being assembled in the yard and installed on board, with BMComposites project managers overseeing the entire process. Due to the use of composite manufacture using CNC-machined female tooling, the parts required very little fairing when compared to traditional aluminium construction – so making significant gains in an extremely weight-sensitive area.
The use of 3D scanning at the outset ensured a perfect fit of the huge components and allowed for full installation of the roof in two days with no requirement for hot works on board.
BMComposites worked closely with the Captain, project management team, designers, engineers and sub-contractors to manage the entire process from initial briefing to installation and final commissioning.
The Sky Lounge refit was described as the ‘jewel’ of the €35m refit, which was credited with a prestigious Judge’s Special Award at the Boat International Superyacht Awards in 2023.
The use of 3D scanning at the outset ensured a perfect fit of the huge components and allowed for full installation of the roof in two days with no requirement for hot works on board.
by BMComposites | Jan 12, 2026
28m Sailing Yacht | Wally
A 28m Wally campaigner engineered with a high-performance four-tank ballast system, capable of transferring tons of water in under six seconds.
To turn the ballast system concept design into a workable system comprising of four tank volumes with fully–automated pick up, transfer and discharge – all integrated into the current GA of the vessel.
Working alongside Pure, Judel/Vrolijk & Innovative Structural Design, BMComposites assisted and completed the final design layout for the entire system. All composite components were constructed in our purpose-built facility.
Ultra-lightweight CFRP parts were produced with the assistance of state-of-the-art technology such as 3D scanning, 3D printing and CAD CAM CNC.
The system setup required special attention to detail for the scoop intake – to fill the tank volumes via a controlled master pump and distribute the necessary water volume as required for the chosen trim. Then, at the right time, it was necessary to transfer several tons of water to the opposite tank in less than 6 seconds.
The physical forces resulting from these processes can have a catastrophic impact on the new and surrounding structures if not designed and installed with complete precision.
BMComposites worked closely with the Captain, Designers, Engineers and sub-contractors to manage the entire process from initial briefing to installation and final commissioning. S/Y Bullitt won IRC Class 1 in the 2023 Middle Sea race in its first outing after the refit.
by BMComposites | Jan 1, 2026
78m Sailing Yacht | Vosper Thornycroft
The iconic M5 flybridge reborn with sleek carbon-fibre hardtops and new helm consoles, replacing the original steel-and-canvas biminis with a modern, integrated design.
BMComposites was commissioned to design, engineer, build and install new carbon-fibre hardtop biminis for the flybridge of the iconic M5 sailing yacht.
The new structures would replace the traditional steel tube and canvas biminis with a modern, sleek design featuring integrated AV and lighting and even electrically operated slide-out sunroofs to protect the helmsman.
Also included in the upgrade was the manufacture and install of two new helm consoles and wheels, designed to complement the new, modernised look of the flybridge.
BMComposites enlisted the services of renowned designer Adriana Monk who, by sympathetically working with the iconic lines of M5, created sleek, modern concepts for the helms and the three new hardtops – two attached fore and aft of the existing transverse arch and one covering the forward area of the huge flybridge.
BMComposites took the concept designs for the new components, through the engineering, tooling and manufacturing phases. Employing cutting-edge technology such as 3D scanning, 3D CAD modelling and CAD CAM tooling manufacture, BMComposites was able to produce the hardtops offsite for later transport to the yard in Italy.
This also ensured the seamless fit of the new components to the existing yacht structures during the rapid installation process.
BMComposites worked closely with the Captain, Designers, Engineers and sub-contractors to manage the entire process from initial briefing to installation and final commissioning. The result, which was featured in a Boat International special report, brought the 30-year-old iconic vessel into the 21st century with a modern look and feel.
by BMComposites | Jun 1, 2025
30m Sailing Yacht | Green Marine
A high-performance 30m racer equipped with a fully automated four-tank water ballast system, built for split-second transfer and total structural precision.
To turn the concept design for the water ballast system design into a working installation comprising four tank volumes, two per side with a fully automated pick up, transfer and discharge all integrated into the current GA of the vessel.
BMComposites was also commissioned to manufacture and install a new sliding foredeck hatch and sail take-down system.
Working alongside Pure, Diverse and Pure Engineering, BMComposites assisted and completed the final design layout for the entire system.
All composite components were constructed in our purpose-built facility in order to produce ultra-lightweight CFRP parts with the assistance of state-of-the-art technology such as 3D scanning, 3D printing and CAD CAM CNC.
The system had to be set up with special attention to detail for the scoop intake to fill the tank volumes via a controlled master pump and distribute the necessary water volume as required for the boat’s trim.
Then at the right time, be able to transfer several tons of water to the opposite tank in around five seconds. All of which can have catastrophic impact on the new and surrounding structures if not designed and installed with complete precision.
BMComposites worked closely with the captain, designers, engineers and sub-contractors to manage the entire process from initial briefing to installation and final commissioning. The boat took first place at the 2023 Palma Vela.
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.
