Monte Carlo Yachts Factory Walkthrough Video

Join us as BoatTest.com takes us on a tour of the Monte Carlo Yachts factory in Monfalcone, Italy:

Hi, Christopher Hughes for BoatTest.com. Today I’m at the world headquarters for Monte Carlo Yachts. We’re going to take a very detailed look at how 21st century luxury motoryachts are designed and manufactured. When you think of elegant motoryachts, one tends to think of Italy. And for that reason, we are here in Monfalcone on major yachting.

Each yacht begins in the open concept office space on the third floor, where the engineers and designers work side by side with the marketing and sales department. This allows for a collaboration of ideas and application of customer wishes that results in an efficient design and execution of world-class motoryachts in a surprisingly short amount of time.

The MCY team was instrumental in the development of proprietary software called Catia. This allows the designers and engineers to work in concert to create lighter, stronger yachts and take customer requests for interior designs and quickly turn them into a reality.

Because of the unusual and proprietary naval architecture, the interior layouts have much fewer limitations compared to a yacht built in the conventional way. This means a customer can specify almost any customization they wish. All materials from which the interior living spaces are made are also at the discretion of the customer.

Monte Carlo Yachts’ décor specialist and the world famous Nuvolari Lenard Design Studio will consult and work together with each client on fabrics, bulkhead coverings, wood selections, carpets, stonework, lighting fixtures and hardware. These materials are selected from the best designers around the world and include names such as Armani Casa, Rubelli, Hermes and Pierre Frey.

Italian leather work is second to none, and many owners choose to use it extensively in their yachts. Woods are also a key ingredient of any motoryacht of this magnitude, and once again, the world finest woods are employed. While all of these elements are being selected, a sample of the boat’s high gloss hull is always on hand for reference.

When entering the main facility itself, I was struck by the overall level of organization and cleanliness. I’ve never seen a boat-building facility as immaculate as this one. And clearly Monte Carlo Yachts takes its cue again from the aerospace industry. Each work area sets the tone for the entire building process. Clean, neat, perfectly structured and efficient.

Here we see decks and bulkheads that have been premade receiving additional assembly of components. Note the coring material that has been custom selected by engineers to deliver the right tensile strength and sound deadening properties.

Although we weren’t allowed to show their proprietary process on video, each hull and deck is meticulously manufactured using only engineered foam coring and the vacuum resin infusing process and a few other trade secrets at a dedicated facility nearby.

This ensures strong and lightweight hulls and decks to help provide improved performance and greater fuel efficiency. MCY also utilizes a patented innovative modular industrial process for the assembly of each yacht, which we again were unable to show you.

The underside of the deck, the part that is typically not seen by the public, is a complex matrix of sandwich lamination designed to impart certain properties to laminate in specific places, all to provide the required strength without using any more resin than necessary. Note the huge fiberglass reinforcing at section beams and the drop-down overhead in what would become the main salon.

The unique aluminum substructure is immensely strong and mounted on the overhead utilizing rubber sound deadening bushings. Wire runs and plumbing are carefully installed with aluminum tracks for longevity and trouble-free operation.

Even the woodworking shop has been brought into the 21st century in terms of light durable laminate, married with traditional joinery skills that have been passed down through generations. Fine veneers are used to cover bulkheads and cabinets to reduce weight and provide an elegant finish. The strips are stitched together with a specially formulated glue to create appealing visual patterns of grain and color. Carpets are usually made from wool and/or silk. Italy is famous for its lacquer work, which is often used on cabinet doors and panels.

Every piece of hardware Monte Carlo Yachts uses has been carefully selected for both form, function and durability. What’s most exciting is when all the components come together in a multi-material piece of furniture, such as this beautiful table top. What is often difficult for anyone to grasp at first is that Monte Carlo Yachts built fiberglass boats with virtually every piece custom designed and handmade, like a giant Fabergé egg.

Not only does a Monte Carlo Yachts look stunning from the outside, but inside there’s even more painstaking workmanship. Every piece of wood is cut, shaped, sanded, finished and installed as a piece of a larger, more complex creation; be it a credenza, galley cabinet, a chest of drawers, table, bed, or a sofa.

Every bulkhead receives its own special coverings as well. Every sofa and chair is built from scratch, from one-off designs and covered with a custom selected upholstery. And every cabinet was designed and built for a specific purpose and to hold designated articles.

When everything is complete on the inside and it has passed the Monte Carlo Yachts’ rigorous quality control inspections, only then is it ready to enter the company’s state-of-the-art painting facility.

There it receives a primer coat, then the yacht remains for 2 days. When the hull is exactly 71.6 degrees Fahrenheit, the hull then finally receives its rich glossy outer coat of paint.

For the next 24 hours the boat stays in this climate-controlled oven until the paint has cured. I hope you’ve enjoyed our look at how Monte Carlo Yachts designs and builds their beautiful yacht. For BoatTest.com, I’m Christopher Hughes.