Coral Ocean

by BMComposites | Jul 8, 2026

Coral Ocean

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.

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The Brief

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.

The Approach

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.

The Result

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.

References

Ahoy Club: World Superyacht Awards 2023.

Boat International: Superyacht Awards 2023 Winner

Polar Star

by BMComposites | Feb 12, 2026

Polar Star

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.

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The 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.

The 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 manufacture 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 sunroofs were also developed in detail and specified in the CAD.

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

The jacuzzi, large enough for 8 people, featured glass panel frontage and underwater lighting. The two large sunpads either side were also part of the scope of supply, manufactured at the BMC facility in Palma and shipped to Barcelona during the extensive refit at MB92.

Final install of the hardtop on board was achieved in two days with no hot works required and minimal impact to other works ongoing on the upper deck. The same was true for the service bar and jacuzzi — the furniture modules were painted off-site and bonded onto the deck in an operation that also lasted only two days, thanks to the detailed prior development of the parts. This allowed the surrounding area to be fully finished in advance.

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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.

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bm-composites-modifications-POLAR STAR FURNITURE-08

bmcomposites-polar-star-jacuzzi-07-credit-Stuart-Pearce

bmcomposites-polar-star-jacuzzi-09-credit-Stuart-Pearce

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References

Boat International: Polar Star — How a 63m Lürssen Explorer Yacht Was Reborn

M5

by BMComposites | Jan 1, 2026

M5

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.

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The Brief

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.

The Approach

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.

The Result

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.