Bahart Lake Balaton Ferry

Bahart (Balatoni Hajózási Zrt.) renewed its fleet in 2022-2023: two modern catamarans and two state-of-the-art ferries were built for Lake Balaton. Carbon Composites Ltd. served as the project’s composite supplier, manufacturing the vessels’ panel elements and structural components for the SAM Shipbuilding (Komárno, Slovakia) shipyard.

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The project was realised based on designs by Werkemotion design studio (Slovakia/Czech Republic), with engineering by MULTI Engineering. The vessels entered service on Lake Balaton in 2023, significantly increasing capacity and travel comfort.

Carbon Composites’ Role in the Project

Composite Panel Manufacture

Carbon Composites Ltd. was responsible for manufacturing the vessels’ exterior and interior composite panel elements. Glass-fibre composite (GRP) technology enables the production of lightweight, durable and corrosion-resistant structures ideal for marine applications.

Manufactured elements:

Exterior cladding panels
Interior structural elements
Deck panels
Wheelhouse composite components

RTM Technology in Shipbuilding

The larger structural elements were produced using RTM (Resin Transfer Molding) technology. This process ensures:

Smooth surfaces on both sides – no post-finishing required
Uniform wall thickness – consistent mechanical properties
Reproducible quality – ideal for series production
Complex geometries – curved surfaces and ribbing in a single step

Tooling & Master-Modell Production

In the first phase of the project we CNC-machined the master models and manufactured the production tools. Our Zimmermann FZ-35 gantry mill’s 3.5 m working area enabled precision machining of the tooling for large-format vessel elements.

Tooling process:

CAD model handover from designer (Werkemotion)
Master-modell CNC machining from model board
Composite tool lamination from the master modell
Tool surface treatment and tempering
Trial production and quality inspection

Marine Composite Requirements

Challenges of the Marine Environment

Composite components used in shipbuilding must meet special requirements:

Environmental resistance:

UV resistance – continuous sun exposure
Water resistance – constant moisture, submerged sections
Temperature fluctuation – -20 °C in winter, +40 °C in summer
Mechanical stress – waves, docking impacts

Quality requirements:

Gelcoat surface with UV stabiliser
Osmosis protection (underwater sections)
Fire-retardant resin systems (passenger areas)
Long-lasting colour stability

Lightweight Benefits

Composite technology offers significant advantages over traditional steel or aluminium shipbuilding:

Weight reduction:

30-40% lighter than steel
Lower fuel consumption
Greater payload capacity

Maintenance:

Does not corrode
No painting required (gelcoat surface)
Long service life with minimal maintenance

Design freedom:

Complex, streamlined shapes
Hydrodynamically optimised hull
Custom design realisation

International Collaboration

SAM Shipbuilding Partnership

SAM Shipbuilding and Machinery (Komárno, Slovakia) is one of Central Europe’s leading shipyards. The collaboration between Carbon Composites Ltd. and SAM during the Bahart project demonstrated that Hungarian composite expertise and Slovak shipbuilding experience complement each other excellently.

Project coordination:

Design: Werkemotion (CZ/SK) + MULTI Engineering
Shipbuilding: SAM Shipbuilding (Komárno, SK)
Composite elements: Carbon Composites (Balatonszőlős, HU)
Client: Bahart (Balatoni Hajózási Zrt., HU)

Delivery & Logistics

The finished vessels reached Lake Balaton via the Danube and the Siófok canal. During the special transport the vessels had to be partially disassembled to pass under low bridges – a factor already considered in the design phase.

Technical Data

Catamaran Specifications

Capacity:

Main deck: 200 seats
Sun deck: 80 seats
Bar and catering unit
Premium wheelhouse

Propulsion:

EUR Stage 5 engines
Reduced emissions
Fuel-efficient

Dimensions:

Length: ~30 metres
Beam: ~8 metres (catamaran)
Passenger capacity: 280 persons

Environmental Sustainability

The new vessels are significantly more environmentally friendly than their predecessors:

50% lower fuel consumption – modern engines + lightweight composite structure
Lower emissions – EUR Stage 5 standard
Reduced noise – passenger comfort and environmental protection
Long service life – durable composite materials, minimal maintenance

Results & Outlook

Successful Commissioning

The vessels commissioned in 2023 have since carried more than 100,000 passengers on Lake Balaton. Passenger feedback is excellent: the modern design, spacious interiors and comfortable seating have elevated the Balaton navigation experience to a new level.

Project results:

4 vessels successfully delivered
On time and within budget
Excellent quality indicators
Positive passenger feedback

Shipbuilding Reference

The Bahart project proves that Carbon Composites Ltd. is capable of performing as a composite supplier on large-volume, complex marine projects. The special requirements of watercraft – UV resistance, water resistance, mechanical loading – were all met.

This reference opens the way to further shipbuilding projects: composite elements for ferries, catamarans, small craft and special watercraft.

Marine composite manufacture presents similar technological challenges to other sectors:

Railway – similarly sized panels, fire-resistance requirements
Aviation – lightweight solutions, strict quality standards
Automotive – series production, surface quality, durability

Carbon Composites Ltd.’s more than 30 years of composite manufacturing experience enables us to serve the specialised needs of diverse industries – from shipbuilding to railway vehicles, from medical devices to the automotive sector.