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 | 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 sailing yacht M5, replacing the original steel tube and canvas biminis with a lightweight, modern structure.
The new design needed to integrate AV and lighting, along with electrically operated slide-out sunroofs to protect the helmsman. The scope also included two new helm consoles and wheels, designed to complement the flybridge’s new look.
BMComposites enlisted designer Adriana Monk, who worked sympathetically with M5’s existing lines to create modern concepts for the helms and three new hardtops: two attached fore and aft of the existing transverse arch, and one covering the forward area of the flybridge.
Taking these concepts through engineering, tooling and manufacture, BMComposites used 3D scanning, 3D CAD modelling and CAD/CAM tooling to produce the hardtops off-site ahead of transport to the yard in Italy. This approach ensured an engineered fit between the new components and the yacht’s existing structure, keeping the on-site installation process efficient.
BMComposites worked closely with the captain, designers, engineers and subcontractors to manage the process from initial briefing through to final commissioning. The completed refit, featured in a Boat International special report, brought the 30-year-old yacht a modern look and feel while retaining her original character.
From refit to bespoke composite structures, our project management team is ready to talk through what’s next.
by BMComposites | Jan 1, 2025
62m Sailing Yacht | Holland Jachtbouw
A 62m Holland Jachtbouw schooner outfitted with three large carbon-fibre deck hatches, engineered from full 3D scans for a flawless, rapid installation.
As part of an award-winning refit at Huisfit in 2022, Athos called on BMComposites to engineer, manufacture and install three large carbon fibre deck hatches, each measuring over 4.5m in length. The existing aluminium hatches had grown too heavy for their hardware, were failing to seal properly, and had become difficult to operate.
Ahead of the yacht’s departure, BMComposites carried out a full 3D scan of the existing deck apertures, including the scupper systems and mating sealing features.
This scan data became the reference for remodelling the new hatches in 3D CAD, alongside a new custom hardware package featuring multiple closing dogs with a central locking system and heavy-duty pantographing hinges.
Design and manufacture was carried out under the oversight of the Bureau Veritas Classification Society, part of BMComposites’ end-to-end project management role on the refit.
After manufacture and painting at BMComposites’ facility in Palma, the hatches were shipped to Huisfit and mounted on board by the BMComposites install team. The extensive use of 3D scanning meant the hatches fitted the existing apertures precisely, allowing rapid installation with minimal impact on other refit work. Athos went on to win Best Refitted Yacht at the World Superyacht Awards 2023.
From refit to bespoke composite structures, our project management team is ready to talk through what’s next.
by BMComposites | Jun 12, 2024
40m Sailing Yacht | Wally 130
A striking 40m Wally 130 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 Black Sails, the 39m Wally superyacht. Given their visually prominent position on board, the consoles demanded precise manufacturing and a finish that would show off the carbon fibre construction beneath.
The visually-striking design and prominent positioning on board called for the precise manufacturing of the components.
The design was split into two modules: a sleek helm pedestal carrying a minimal set of engine and thruster controls, and a separate switch panel for hydraulic and sail control buttons that pivots out from the yacht’s side coamings using a custom-designed soft-eject closing mechanism. Both were finished in a clear coating to leave the carbon fibre construction visible.
The helms also feature a back-lit trim line running around the periphery of each pedestal, achieved by developing a technique to inlay laser wire directly into the component during manufacture.
The result is a set of helm consoles that combine a minimal, functional control layout with a finish that shows off the precision of the underlying carbon fibre construction, a fitting complement to Black Sails’ distinctive design.
