Golf club head with impact response modulator

Abstract

Golf club heads have an Impact Response Modulator disposed in the sole to improve ball flight characteristics. The Impact Response Modulator includes a casing with a plurality of casing walls that form an aperture therebetween. The club head further comprises a faceplate with a sole return that integrally forms the entire casing. The faceplate structurally reinforces the IRM by forming the casing walls out of high-strength material, thereby improving faceplate deflection while maintaining sufficient durability.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This is a continuation of U.S. patent application Ser. No. 19 / 255,859, filed on Jun. 30, 2025, which claims the benefit of U.S. Provisional Application No. 63 / 665,985, filed on Jun. 28, 2024, and U.S. Provisional Application No. 63 / 671,687, filed on Jul. 15, 2024, all of which are incorporated in their entirety.FIELD OF INVENTION

[0002] This invention generally relates to golf equipment, and more particularly, to golf club heads having sole openings to increase the flexure of the strike face.BACKGROUND

[0003] The strike face of a golf club head deflects upon impact with a golf ball to impart ball flight characteristics such as ball speed, launch angle, and spin rate. More deflection will increase energy transfer between the club head and the golf ball at impact, thereby increasing ball speed. Strike face deflection also influences the launch angle at impact as well as the amount of backspin imparted to the golf ball, wherein a lower backspin rate leads to a more piercing ball flight that cuts through the air and increases carry distance. Traditionally, certain golf club heads, particularly wood-type golf club heads, include features that increase strike face deflection, such as slits, slots, openings, channels, flexures, or other known features that abruptly change geometry and / or create discontinuities in the club head. Features that increase strike face deflection, however, often increase resulting stresses in the area adjacent said features, thereby reducing club head durability. Conventional golf club heads fail to increase strike face deflection without compromising club head durability.BRIEF DESCRIPTION OF THE DRAWINGS

[0004] FIG. 1 is a top, front, toe-side perspective view of a golf club head according to the present invention.

[0005] FIG. 2 is a bottom, front, toe-side perspective view of the golf club head of FIG. 1.

[0006] FIG. 3 is a front, elevation view of the golf club head of FIG. 1.

[0007] FIG. 4 is a toe-side, elevation view of the golf club head of FIG. 1.

[0008] FIG. 5 is a bottom, rear, toe-side perspective view of a golf club head according to the present invention.

[0009] FIG. 6 is a bottom, rear, toe-side perspective view of a golf club head according to the present invention.

[0010] FIG. 7 is a detailed, plan view of the golf club head of FIG. 1, in cross-section.

[0011] FIG. 8 is a toe-side, detailed, elevation view of the golf club head of FIG. 1, in cross-section.

[0012] FIG. 9 is a detailed, heel-side, elevation view of a golf club head according to the present invention, in cross-section.

[0013] FIG. 10 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross-section.

[0014] FIG. 11 is a toe-side, detailed, elevation view of a golf club head according to the present invention, in cross-section.

[0015] FIG. 12 is a rear, heel-side perspective view of a golf club head faceplate.

[0016] FIG. 13 is a heel-side, elevation view of a golf club head according to the present invention, in cross-section.

[0017] FIG. 14 is a rear, heel-side perspective view of a golf club head faceplate.

[0018] FIG. 15 is a heel-side, detailed, elevation view of a golf club head comprising the faceplate of FIG. 14, in cross-section.

[0019] FIG. 16 is a detailed, heel-side, elevation view of a golf club head according to the present invention, in cross-section.

[0020] FIG. 17 is a detailed, heel-side, elevation view of a golf club head according to the present invention, in cross-section.

[0021] FIG. 18 is a detailed, heel-side, elevation view of a golf club head according to the present invention, in cross-section.

[0022] FIG. 19 is a detailed, heel-side, elevation view of a golf club head according to the present invention, in cross-section.

[0023] FIG. 20 is a bottom view of a golf club head according to the present invention.

[0024] FIG. 21 is a plan view of the golf club head of FIG. 20.

[0025] FIG. 22 is a rear, heel-side perspective view of a golf club head faceplate.

[0026] FIG. 23 is a plan view of the golf club head faceplate of FIG. 21.

[0027] FIG. 24 is a front, heel-side perspective view of a golf club head body with the faceplate removed.

[0028] FIG. 25 is a rear, heel-side perspective view of a golf club head faceplate.

[0029] FIG. 26 is a plan view of the golf club head faceplate of FIG. 25.

[0030] FIG. 27 is a front, heel-side perspective view of a golf club head body with the faceplate removed.DETAILED DESCRIPTION

[0031] Described herein are various embodiments of wood-type golf club heads (i.e. drivers, fairway woods, or hybrids) comprising an impact response modulator (hereafter “IRM”) in the sole. The IRM strategically weakens the sole to increase strike face deflection, thereby improving ball flight performance. The IRM comprises a casing that forms one or more walls defining an aperture into the club head. The aperture is an opening through the sole that communicates between the environment surrounding the club head and the interior cavity of the club head. The IRM further comprises an insert disposed within the aperture and formed of a flexible, polymeric material.

[0032] The faceplate can be a monolithic component that forms at least a portion of the strike face and comprises a sole return that forms both the casing and a forward portion of the sole. At impact, stress from the strike face flows into the forward portion of the sole, where the casing resides. Forming the casing by high-strength faceplate material reduces stress in the casing walls. Accordingly, the casing walls can have a reduced thickness and / or be placed closer to the strike face without exceeding the yield strength of the high-strength material, thereby increasing strike face deflection.

[0033] In some embodiments, the club head comprises a body and a faceplate coupled together, wherein the faceplate forms the entire casing. More specifically, the faceplate comprises a sole return that forms the entire casing and the entire aperture resides within the sole return. The body comprises a body material that is easily castable to form various complex club head geometries. The faceplate comprises a high-strength faceplate material with a yield strength greater than 175 ksi (i.e., C300 steel, C350 steel, Ti-9s, Ti-9s+, etc.) The faceplate material is more durable than the body material and is suitable to withstand direct impact with a golf ball. The body forms no portion of the casing.

[0034] The faceplate integrally forming the entire casing and aperture can be formed by an additive manufacturing process, such as 3D printing, metal injection molding, casting, or any other suitable forming method to ensure manufacturability of complex geometries. The faceplate comprises a complex geometry including at least a sole return and the various casing walls. In other embodiments, the faceplate further comprises a crown return, a toe return, a heel return, portions of the hosel, or a combination thereof. In some embodiments, 3D-printing the faceplate allows a unitary component with a complex geometry forming the crown return, sole return, and toe return.

[0035] In general, a monolithically forged or formed component can have no more than two “bends” in a given cross-section, wherein a “bend” refers to adjacent surfaces or portions of the component being significantly angled relative to each other. For example, a monolithically forged or formed faceplate can have no more than two bends in a vertical (i.e., crown-to-sole) cross section and no more than two bends in a horizontal (i.e., heel-to-toe) cross section. Components with more than two bends in given cross section may not provide sufficient clearance for a forging tool to be removed post-manufacture.

[0036] The faceplate is formed through 3D printing or another additive manufacturing process. The faceplate geometry is not limited to two bends in a given cross section. 3D printing thereby improves club head durability by allowing for more intricate casing wall geometries, and more robust combinations of sole returns, crown returns, heel returns, and toe returns. As such, more of the club head can be formed by a high-strength material, thereby reducing stress and allowing the faceplate walls to be thinned to increase strike face deflection. Specifically, in one embodiment, the 3D printed faceplate comprises a sole return that integrally forms the entire casing and aperture, a crown return that strengthens the crown, and a toe return that strengthens the toe. This configuration is a complicated geometry with multiple bends that is not suitable for casting, forging, or forming, and is therefore advantageously formed through 3D printing.

[0037] The IRM uses high-strength material to increase strike face deflection while maintaining durability. For example, both the casing front wall and the casing rear wall can be integrally formed by high-strength material (i.e., the faceplate material).I. Definitions

[0038] The terms “first,”“second,”“third,”“fourth,” and the like in the description and in the claims, if any, are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments described herein are, for example, capable of operation in sequences other than those illustrated or otherwise described herein. Furthermore, the terms “include,” and “have,” and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, system, article, device, or apparatus that comprises a list of elements is not necessarily limited to those elements but may include other elements not expressly listed or inherent to such process, method, system, article, device, or apparatus.

[0039] The terms “left,”“right,”“front,”“back,”“top,”“bottom,”“over,”“under,” and the like in the description and in the claims, if any, are used for descriptive purposes and not necessarily for describing permanent relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments of the apparatus, methods, and / or articles of manufacture described herein are, for example, capable of operation in other orientations than those illustrated or otherwise described herein.

[0040] The term “strike face,” as used herein, refers to a club head front surface that is configured to strike a golf ball. The term “strike face” can be used interchangeably with the term “face.”

[0041] The strike face 102 is bounded by an outer edge referred to as a “strike face perimeter.” The strike face perimeter is defined where the curvature of the golf club head 100 deviates from a bulge curvature and / or roll curvature of the strike face 102 (defined below). The strike face perimeter includes at least an upper edge 118 that defines a transition between the strike face 102 and the crown 110 and a leading edge 103 that defines a transition from the strike face 102 to the sole 112. The upper edge 118 defines a face apex (FA), located at the intersection between the upper edge 118 and the YZ plane (described below). The leading edge 103 defines a face nadir (FN) located at the intersection between the leading edge 103 and the YZ plane. The strike face 102 further defines a face center (FC), which is the geometric centerpoint of the strike face perimeter, illustrated in FIG. 3. The face center (FC) can be located in accordance with the definition of a golf governing body such as the United States Golf Association (USGA).

[0042] The strike face 102 comprises a bulge curvature and a roll curvature. The bulge curvature is the curvature of the strike face 102 in the heel-to-toe direction. The roll curvature is the curvature of the strike face in a crown-to-sole direction. The bulge curvature and the roll curvature each respectively comprise a bulge radius and a roll radius defining the radii of curvature associated with each of the bulge curvature and the roll curvature. The bulge curvature and / or the roll curvature can comprise one or more radii.

[0043] The golf club head 100 defines a ground plane (GP) as a reference plane associated with the surface on which a golf ball is placed. The ground plane GP is a horizontal plane tangent to the sole 112 in the address position. The ground plane GP is illustrated in FIG. 3.

[0044] The golf club head 100 defines a loft plane 15 as a plane that is tangent to the strike face 102 at the face center (FC). The loft plane 15 is illustrated in FIG. 4.

[0045] The golf club head 100 defines a loft angle 20 as the angle measured between the loft plane 15 and the XY plane (defined below). The loft angle 20 is illustrated in FIG. 4.

[0046] The golf club head 100 defines a lie angle 25 as the angle between a hosel axis 30, extending longitudinally through the hosel 105, and the ground plane GP. The lie angle 25 is measured from a front view of the golf club head 100, as illustrated in FIG. 3.

[0047] The golf club head 100 can define an address position, wherein the golf club head 100 is oriented such that the golf club head 100 forms its intended loft angle 20 and lie angle 25. For example, in the address position, the loft plane 15 and the XY plane form the intended loft angle 20 between one another. Likewise, in the address position, the hosel axis 30 and the ground plane GP form the intended lie angle 25 between one another.

[0048] As illustrated in FIGS. 3 and 4, the golf club head 100 defines a primary coordinate system centered about the face center (FC). The primary coordinate system comprises an X-axis 40, a Y-axis 50, and a Z-axis 60. The X-axis 40 extends in a heel-to-toe direction, parallel to the ground plane GP. The X-axis 40 is positive towards the heel 104 and negative towards the toe 106. The Y-axis 50 extends in a crown-to-sole direction and is orthogonal to both the ground plane GP and the X-axis 40. The Y-axis 50 is positive towards the crown 110 and negative towards the sole 112. The Z-axis 60 extends in a front-to-rear direction, parallel to the ground plane GP, and is orthogonal to both the X-axis 40 and the Y-axis 50. The Z-axis 60 is positive towards the strike face 102 and negative towards the rear 111.

[0049] The primary coordinate system, as described herein, defines an XY plane as a vertical plane extending along the X-axis 40 and the Y-axis 50. The primary coordinate system defines an XZ plane as a horizontal plane extending along the X-axis 40 and the Z-axis 60. The primary coordinate system further defines a YZ plane as a vertical plane extending along the Y-axis 50 and the Z-axis 60. The XY plane, the XZ plane, and the YZ plane are all perpendicular to one another and intersect at the primary coordinate system origin located at the face center (FC). In these or other embodiments, the golf club head 100 can be viewed from a front view when the strike face 102 is viewed from a direction perpendicular to the XY plane. Further, in these or other embodiments, the golf club head 100 can be viewed from a side view when the heel 104 or the toe 106 is viewed from a direction perpendicular to the YZ plane.

[0050] The golf club head 100 comprises a club head center of gravity (hereafter “CG” or “club head CG”), referring to the point at which the mass is centered within the golf club head 100. The club head CG is illustrated in FIGS. 3 and 4.

[0051] The “body depth,” or “depth” DB of the club head 100, as used herein, refers to a front-to-rear dimension measured across the body. Referring to FIG. 4, the body depth DB is measured parallel to the Z-axis 60 from the leading edge 103 to the rearward-most point of the body 101.

[0052] The “body height,” or “height” HB of the club head 100, as described herein, can refer to a crown-to-sole dimension measured across the body 101. Referring to FIG. 3, the body height HB can be measured as a vertical distance (parallel to the Y-axis 50) between the ground plane GP and the highest point of the crown 110. In many embodiments, the height HB can be measured according to a golf governing body such as the United States Golf Association (USGA).

[0053] The “body width,” or “width” WB of the club head 100, as described herein, can refer to a heel-to-toe dimension measured across the body. Referring to FIG. 3, the body width WB can be measured parallel to the X-axis 40 from a body heel apex (BHA) to a body toe apex (BTA). The body toe apex (BTA) is defined as the toeward-most point of the body 101. The body heel apex (BHA) is heelward-most point of the heel 104 that is located at a height 0.875 mm from the ground plane GP. In many embodiments, the body width (WB) can be measured according to a golf governing body such as the United States Golf Association (USGA). The ranges specified for the body depth (DB), body height (HB), and body width (WB) can be designed in accordance with the USGA regulations.

[0054] The “Impact Response Modulator” or “IRM” described herein, comprises a casing, an aperture, and an insert. The IRM is a club head feature that increases strike face deflection at impact with a golf ball.

[0055] The “casing” refers to a component of the IRM that comprises one or more walls and or structures defining an aperture that communicates between the environment surrounding the club head and the interior cavity of the club head.

[0056] “Driver” golf club heads as used herein comprise a loft angle less than approximately 16 degrees, less than approximately 15 degrees, less than approximately 14 degrees, less than approximately 13 degrees, less than approximately 12 degrees, less than approximately 11 degrees, or less than approximately 10 degrees. Further, in many embodiments, “driver golf club heads” as used herein comprises a volume greater than approximately 400 cc, greater than approximately 425 cc, greater than approximately 445 cc, greater than approximately 450 cc, greater than approximately 455 cc, greater than approximately 460 cc, greater than approximately 475 cc, greater than approximately 500 cc, greater than approximately 525 cc, greater than approximately 550 cc, greater than approximately 575 cc, greater than approximately 600 cc, greater than approximately 625 cc, greater than approximately 650 cc, greater than approximately 675 cc, or greater than approximately 700 cc. In some embodiments, the volume of the driver can be approximately 400 cc-600 cc, 425 cc-500 cc, approximately 500 cc-600 cc, approximately 500 cc-650 cc, approximately 550 cc-700 cc, approximately 600 cc-650 cc, approximately 600 cc-700 cc, or approximately 600 cc-800 cc.

[0057] Driver embodiments can comprise a body height HB between 2.0 and 3.0 inches. In some driver embodiments, the body height HB can be between 2.0 and 2.2 inches, between 2.2 and 2.4 inches, between 2.4 and 2.6 inches, between 2.6 and 2.8 inches, or between 2.8 and 3.0 inches. In some driver embodiments, the body height HB can be greater than 2.0 inches, greater than 2.2 inches, greater than 2.4 inches, greater than 2.6 inches, greater than 2.8 inches, or greater than 3.0 inches.

[0058] Driver embodiments can comprise a body width WB between 4.4 and 5.0 inches. In some driver embodiments, the body width WB can be between 4.4 and 4.6 inches, between 4.6 and 4.8 inches, or between 4.8 and 5.0 inches. In some driver embodiments, the body width WB can be greater than 4.4 inches, greater than 4.6 inches, greater than 4.8 inches, or greater than 5.0 inches.

[0059] Driver embodiments can comprise a body depth DB between 4.3 and 4.9 inches. In some driver embodiments, the body depth DB can be between 4.3 and 4.5 inches, between 4.5 and 4.7 inches, or between 4.7 and 4.9 inches. In some driver embodiments, the body depth DB can be greater than 4.3 inches, greater than 4.5 inches, greater than 4.7 inches, or greater than 4.9 inches.

[0060] “Fairway wood” golf club heads as used herein comprise a loft angle less than approximately 35 degrees, less than approximately 34 degrees, less than approximately 33 degrees, less than approximately 32 degrees, less than approximately 31 degrees, or less than approximately 30 degrees. Further, in some embodiments, the loft angle of the fairway wood club heads can be greater than approximately 12 degrees, greater than approximately 13 degrees, greater than approximately 14 degrees, greater than approximately 15 degrees, greater than approximately 16 degrees, greater than approximately 17 degrees, greater than approximately 18 degrees, greater than approximately 19 degrees, or greater than approximately 20 degrees. For example, in other embodiments, the loft angle of the fairway wood can be between 12 degrees and 35 degrees, between 15 degrees and 35 degrees, between 20 degrees and 35 degrees, or between 12 degrees and 30 degrees.

[0061] Further, “fairway wood” golf club heads as used herein comprises a volume less than approximately 400 cc, less than approximately 375 cc, less than approximately 350 cc, less than approximately 325 cc, less than approximately 300 cc, less than approximately 275 cc, less than approximately 250 cc, less than approximately 225 cc, or less than approximately 200 cc. In some embodiments, the volume of the fairway wood can be approximately 150 cc-200 cc, approximately 150 cc-250 cc, approximately 150 cc-300 cc, approximately 150 cc-350 cc, approximately 150 cc-400 cc, approximately 300 cc-400 cc, approximately 325 cc-400 cc, approximately 350 cc-400 cc, approximately 250 cc-400 cc, approximately 250-350 cc, or approximately 275-375 cc.

[0062] Fairway wood embodiments can comprise a body height HB between 1.25 and 1.75 inches. In some fairway wood embodiments, the body height HB can be between 1.25 and 1.40 inches, between 1.40 and 1.55 inches, or between 1.55 and 1.75 inches.

[0063] Fairway wood embodiments can comprise a body width WB between 3.75 and 4.5 inches. In some fairway wood embodiments, the body width WB can be between 3.75 and 4.0 inches, between 4.0 and 4.25 inches, or between 4.25 and 4.5 inches.

[0064] Fairway wood embodiments can comprise a body depth DB between 3.0 and 4.0 inches. In some fairway wood embodiments, the body depth DB can be between 3.0 and 3.3 inches, between 3.3 and 3.6 inches, between 3.6 and 3.8 inches, or between 3.8 and 4.0 inches.

[0065] “Hybrid” golf club heads as used herein comprise a loft angle less than approximately 40 degrees, less than approximately 39 degrees, less than approximately 38 degrees, less than approximately 37 degrees, less than approximately 36 degrees, less than approximately 35 degrees, less than approximately 34 degrees, less than approximately 33 degrees, less than approximately 32 degrees, less than approximately 31 degrees, or less than approximately 30 degrees. Further, in many embodiments, the loft angle of the hybrid can be greater than approximately 16 degrees, greater than approximately 17 degrees, greater than approximately 18 degrees, greater than approximately 19 degrees, greater than approximately 20 degrees, greater than approximately 21 degrees, greater than approximately 22 degrees, greater than approximately 23 degrees, greater than approximately 24 degrees, or greater than approximately 25 degrees.

[0066] Further, “hybrid” golf club heads as used herein comprise a volume less than approximately 200 cc, less than approximately 175 cc, less than approximately 150 cc, less than approximately 125 cc, less than approximately 100 cc, or less than approximately 75 cc. In some embodiments, the volume of the hybrid can be approximately 100 cc-150 cc, approximately 75 cc-150 cc, approximately 100 cc-125 cc, or approximately 75 cc-125 cc.

[0067] Other features and aspects will become apparent by consideration of the following detailed description and accompanying drawings. Before any embodiments of the disclosure are explained in detail, it should be understood that the disclosure is not limited in its application to the details or embodiment and the arrangement of components as set forth in the following description or as illustrated in the drawings. The disclosure is capable of supporting other embodiments and of being practiced or of being carried out in various ways. It should be understood that the description of specific embodiments is not intended to limit the disclosure from covering all modifications, equivalents and alternatives falling within the spirit and scope of the disclosure. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.II. General Description of a Golf Club Head

[0068] Various embodiments of a golf club comprising a 3D printed faceplate with a sole return that integrally forms the entire casing and aperture are illustrated in the figures. A golf club is generally understood to comprise a club head, a shaft, and a grip. The club head is configured to receive the shaft, and the grip is secured to the shaft.

[0069] Referring to FIGS. 1 and 2, the club head 100 defines a crown 110, a sole 112 opposite the crown 110, a heel 104, a toe 106, a front 108, a rear 111 and a strike face 102. The club head 100 further comprises a hosel 105, which is configured to receive the shaft. In some embodiments, as illustrated in the embodiment of FIGS. 1 and 2, the club head 100 comprises a body 101 and a faceplate 114 coupled together to form an interior cavity. The body 101 forms at least a portion of the crown 110, at least a portion of the sole 112, at least a portion of the heel 104, and at least a portion of the toe 106. The faceplate 114 forms at least a portion of the strike face 102. As discussed in further detail below, the faceplate 114 further comprises a sole return 116 that forms at least a forward portion of the sole 112, as well as integrally forms the entire casing and aperture. Specific configurations of the body 101 and the faceplate 114 are described in further detail below. In some embodiments, the faceplate is joined to the body through a simple, permanent joining process, such as welding or brazing. In other embodiments, the faceplate can be joined to the body through adhesive or mechanical coupling means.

[0070] The features discussed below are demonstrated on club head 100. While different embodiments may comprise different numbering schemes (i.e., 1xx, 2xx, 3xx numbering schemes, etc.) similar elements are numbered similarly between embodiments (i.e., club head 100 comprises a crown 110 and a sole 112, whereas club head 200 comprises a crown 210 and a sole 212). Any one or more of the features below can be used in combination with one another.

[0071] The body 101 comprises a body material that provides sufficient structural strength and is easily formed into complex geometries. In many embodiments, the body material is a metallic material that is easily castable. In some embodiments, the body material can comprise one or more materials such as steel, stainless steel, tungsten, aluminum, titanium, vanadium, chromium, cobalt, nickel, other metals, or metal alloys. In some embodiments, the body material can comprise a Ti-8Al-1Mo-1V alloy, or a 17-4 stainless steel. In some embodiments, the body material can be formed from Ni (Nickel)-Co (Cobalt)-Cr (Chromium)-Steel Alloy, 565 Steel, AISI type 304 or AISI type 630 stainless steel, 17-4 stainless steel, 431 stainless steel, 304 stainless steel, 316 stainless steel, 8620 carbon steel, 1020 carbon steel, 1025 carbon steel, 17-7 PH stainless steel, 303 stainless steel, AUS-8 stainless steel, and gray cast iron or ductile iron titanium alloys such as, but not limited to, Ti-6Al-4V (Ti-6-4), Ti-4Al-4Mo-2Sn-0.5Si (Ti-4-4-2-0.5Si), Ti-6Al-2Sn-4Zr-2Mo (Ti-6-2-4-2), Ti-5Al-2.5Sn, Ti-3Al-2.5V, Ti-6Al-1Zr-1Nb-1Mo (Ti-6-1-1-1), Ti-0.3Mo-0.8Ni, and Ti-6Al-7Nb, an amorphous metal alloy, or other similar metals. Generally, the body material can comprise a yield strength between 145 and 165 ksi.

[0072] In some embodiments, the body 101 comprises a multi-material construction including one or more lightweight materials, such as a lightweight composite material, in addition to the metallic body material. In some embodiments, a portion of the crown 110, a portion of the sole 112, a portion of the heel 104, a portion of the toe 106, or a combination thereof can be formed by a composite material. In such embodiments, the club head 100 can comprise one or more composite panels. In some embodiments, referring to FIG. 5, the club head 100 can comprise a crown panel 196 made of a composite material. The crown panel 196 can comprise a heel wrap 197a and a toe wrap 197b that each wrap over the heel 104 and toe 106, respectively, and form portions of the sole 112. Further in some embodiments, the club head 100 can comprise a sole panel 198 forming at least a portion of the sole 112. In other embodiments, referring to FIG. 6, the club head 100 can comprise a central panel 199 that continuously wraps around the crown 110, sole 112, heel 104, toe 106, or various combinations thereof.

[0073] In some embodiments, the one or more composite panels can comprise a composite formed from a polymer resin and reinforcing fiber. The polymer resin can comprise a thermoset or a thermoplastic resin. In some embodiments, the one or more composite panels can comprise a carbon fiber composite material having multiple layers of unidirectional carbon fibers formed as a single, continuous piece. In some embodiments, the one or more composite panels may comprise a bi-directional woven carbon fiber composite material having a single layer formed as a single, continuous piece. In some embodiments, the one or more composite panels can comprise a fiber reinforced thermo-plastic material. The one or more composite panels can be extruded, compression molded, injection molded, blow molded or bladder molded, 3-D printed, or otherwise formed by any other appropriate forming means.

[0074] The faceplate 114 comprises a faceplate material having sufficient strength to withstand repeated impacts with a golf ball. As such, the faceplate material comprises a greater yield strength than the body material and is thus more durable. In some embodiments, the faceplate material can be a high-strength steel alloy, for example, but not limited to Carpenter 455, Carpenter 475, HT1770, M455 (H900), M475 (H975), 4140, 4340, C300, C350, 6150 steel, K301, Carpenter 158, Carpenter 450, Carpenter 465, Carpenter 431, Inconel 718, Aermet 100, Maraging Steel (MSL 350, MSL 450), H13 Tool Steel, 17-4 PH Stainless Steel, 18Ni (300M), S7 Tool Steel, D2 Tool Steel, 440C Stainless Steel, SKD11, SAE 9260, 10B21 Boron Steel, 52100 Steel, Tungsten Carbide Steel, Viking 80, or 4130 Chromoly Steel.

[0075] In other embodiments, the faceplate material can be a high-strength titanium alloy, for example, but not limited to Ti-3-8-6-4-4, Ti-10-2-3, Ti 15-3-3-3, Ti 15-5-3, Ti185, Ti 6-6-2, Ti-7s, Ti-9s, Ti-92, Ti-6Al-4V (Ti-6-4), Ti-3Al-8V-6Cr-4Mo-4Zr (Ti-3-8-6-4-4), Ti-10V-2Fe-3Al (Ti-10-2-3), Ti-15V-3Cr-3Al-3Sn (Ti-15-3-3-3), Ti-15Mo-5Zr-3Al (Ti-15-5-3), Ti-185, Ti- 6Al-6V-2Sn (Ti-6-6-2), Ti-7Al-4Mo (Ti-7s), Ti-9Al-2Mo (Ti-9s), Ti-9s+, Ti-9Al-2V (Ti-92), Ti-8Al-1Mo-1V (Ti-8-1-1), Ti-5Al-5Mo-5V-3Cr (Ti-5553), Ti-6Al-2Sn-4Zr-2Mo (Ti-6-2-4-2), Ti-6Al-2Sn-4Zr-6Mo (Ti-6-2-4-6), Ti-6Al-7Nb, Ti-5Al-5Mo-5V-1Cr-1Fe (Ti-55511), Ti-13V-11Cr-3Al, Ti-1100, Ti-6Al-2.75Sn-4Zr-0.4Mo-0.45Si-0.1Y (IMI 829), Ti-5Al-2Sn-2Zr-4Mo-4Cr (Ti-17), Ti-9-2-2, Beta-C Titanium (Ti-Beta C), or Ti-4Al-4Mo-2Sn-0.5Si (Ti-4-4-2-0.5Si).

[0076] The faceplate material comprises a high yield strength. In some embodiments, the faceplate material comprises a yield strength greater than 175 ksi, greater than 185 ksi, greater than 195 ksi, greater than 200 ksi, greater than 210 ksi, greater than 220 ksi, greater than 230 ksi, greater than 240 ksi, or greater than 250 ksi. The faceplate material can comprise a higher yield strength than the body material. In some embodiments, the club head 100 comprises a faceplate strength ratio comparing the yield strength of the faceplate material to the yield strength of the body material. In some embodiments, the faceplate strength ratio can be greater than 1.25, greater than 1.35, greater than 1.45, greater than 1.55, greater than 1.65, greater than 1.75, greater than 1.85, greater than 1.95 or greater than 2.0.III. Impact Response Modulator

[0077] The golf club head 100 comprises an Impact Response Modulator 120 (hereafter “IRM”) reinforced by high-strength material that increases strike face deflection at impact with a golf ball while maintaining sufficient durability. Referring to FIG. 2, the IRM 120 is disposed in the sole 112. The IRM 120 strategically weakens the sole 112 to increase strike face deflection. The IRM 120 comprises a casing 130 surrounding an aperture 140 that is configured to receive an insert 170. As illustrated in FIG. 2, the IRM 120 extends in a substantially heel-to-toe direction across the sole 112 to increase strike face deflection.

[0078] The casing 130 is the structure that forms and surrounds the aperture 140. The entire casing 130 can be formed by the high-strength faceplate 114. As illustrated in FIGS. 7 and 8, the casing 130 comprises a front wall 132 proximate the strike face 102, yet separated therefrom by a forward sole region 166, a rear wall 142 spaced rearward from the front wall 132, a heel wall 152 extending between the front wall 132 and the rear wall 142 at a heel end of the casing 130 and a toe wall 154 extending between the front wall 132 and the rear wall 142 at a toe end of the casing 130. The front wall 132, the rear wall 142, the heel wall 152, and the toe wall 154 each extend upward from the sole 112. The front wall 132, the rear wall 142, the heel wall 152, and the toe wall 154 of the casing 130 collectively border and define the aperture 140 therebetween. The aperture 140 is a through-hole fluidly communicating between the club head exterior and the interior cavity. As described above, the entire casing 130 is formed by the sole return 116, and therefore the entire aperture 140 is thereby formed within the sole return 116. The front wall 132 comprises a front wall front surface 134 disposed towards the strike face 102, a front wall rear surface 136 disposed towards the aperture 140, a front wall base 133, and a front wall top surface 138 opposite the front wall base 133. The rear wall 142 comprises a rear wall front surface 144 disposed towards the aperture 140, a rear wall rear surface 146 disposed towards the rear 111, a rear wall base 143, and a rear wall top surface 148 opposite the rear wall base 143.

[0079] The casing 130 is spaced rearwardly from the strike face 102. As best illustrated in FIGS. 8 and 9 the front wall 132 is separated from the strike face 102 by a forward sole region 166. The forward sole region 166 is integrally formed by the faceplate 114. More specifically, the forward sole region 166 is formed by the sole return 116. The forward sole region 166 separates the front wall 132 from the strike face 102 by an offset distance OD, which is described in further detail below. As such, the casing 130 comprises a front wall 132 that forms the aperture 140 and is distinct from the strike face 102. Further, as best illustrated in FIG. 9, the strike face 102, the forward sole region 166, and the front wall 132 combine to collectively define a U-shaped trough 175. The U-shaped trough 175 can be disposed toward the interior cavity 107 and can be in fluid communication therewith. The U-shaped trough 175 can run along the length of the casing 130, between the front wall 132 and the strike face 102.

[0080] The forward sole region 166 balances durability and strike face deflection by spacing the casing 130 and the aperture 140 rearward of the strike face 102. If not for the forward sole region 166, the casing 130 and / or the aperture 140 would directly abut the strike face 102. In such cases, the impact stress and in the casing 130 and the strike face 102 would be so high that the strike face 102 and / or the casing walls would need to be significantly thickened to preserve durability. Doing so would hinder strike face deflection such that any performance gains achieved by the inclusion of the IRM 120 would be lost or greatly diminished. Spacing the casing 130 and the aperture 140 rearward of the strike face 102 by the forward sole region 166 allows the strike face 102 and casing walls to be thinned, therefore increasing strike face deflection.

[0081] The casing 130 can comprise a front wall height FWH, as best illustrated in FIG. 9, measured as the distance between the front wall base 133 and the front wall top surface 138, along the front wall rear surface 136. The front wall height FWH can be selected to increase strike face deflection without compromising durability. Specifically, decreasing the front wall height FWH increases strike face deflection, but potentially decreases durability. Reinforcing the casing 130 with high-strength material, as described herein, allows the front wall height FWH to be reduced while maintaining durability. The front wall height FWH can be constant along the length of the casing 130, or the front wall height FWH can vary along the length of the casing 130. In many embodiments, the front wall height FWH can be measured within a vertical plane extending through the face center (FC) in a front-to-back direction. In some embodiments, the front wall height FWH can be between 0.050 and 0.10 inch, 0.10 and 0.20 inch, 0.20 and 0.30 inch, 0.30 and 0.40 inch, between 0.40 and 0.50 inch. In some embodiments, the front wall height FWH can be less than 0.50 inch, less than 0.40 inch, less than 0.30 inch, less than 0.20 inch, or less than 0.10 inch. 3D printing the faceplate 114 and forming the entire casing 130 out of high-strength faceplate material allows the front wall height FWH to be reduced, which, as discussed in Example 2 below, improves ball speed and spin rate.

[0082] The casing 130 also comprises an offset distance OD, as best illustrated in FIG. 9, measured as the distance from the leading edge 103 to the front wall base 133, in a strike face-to-rear direction. The casing offset distance OD can be selected to increase strike face deflection without compromising durability. Specifically, decreasing the offset distance OD increases strike face deflection, but potentially decreases durability. Reinforcing the casing 130 with high-strength material, as described herein, allows the offset distance OD to be reduced while maintaining durability. In many embodiments, the offset distance OD can be measured within a vertical plane extending through the face center (FC) in a front-to-back direction. In some embodiments, the offset distance OD can be between 0.075 and 0.10 inch, 0.10 and 0.20 inch, 0.20 and 0.30 inch, 0.30 and 0.40 inch, 0.40 and 0.50 inch, 0.50 and 0.60 inch, 0.60 and 0.70 inch, 0.70 and 0.80 inch, 0.80 and 0.90 inch, or between 0.90 and 1.00 inch. In some embodiments, the offset distance can be less than 1.0 inch, less than 0.90 inch, less than 0.80 inch, less than 0.70 inch, less than 0.60 inch less than 0.50 inch, less than 0.40 inch, less than 0.30 inch, less than 0.20 inch, or less than 0.10 inch. In some embodiments, the casing offset distance OD can be 0.075 inch, 0.080 inch, 0.085 inch, 0.090 inch, 0.095 inch, 0.10 inch, 0.15 inch, 0.20 inch, 0.25 inch, 0.30 inch, 0.35 inch, 0.40 inch, 0.45 inch, 0.50 inch, 0.55 inch, 0.60 inch, 0.65 inch, 0.70 inch, 0.75 inch, 0.80 inch, 0.85 inch, 0.90 inch, 0.95 inch, or 1.0 inch. In some embodiments, the offset distance OD can be greater than 0.075 inch, greater than 0.080 inch, greater than 0.085 inch, greater than 0.090 inch, greater than 0.095 inch, greater than 0.10 inch, greater than 0.15 inch, greater than 0.20 inch, greater than 0.25 inch, greater than 0.30 inch, greater than 0.35 inch, greater than 0.40 inch, greater than 0.45 inch, greater than 0.50 inch, greater than 0.55 inch, greater than 0.60 inch, greater than 0.65 inch, greater than 0.70 inch, greater than 0.75 inch, greater than 0.80 inch, greater than 0.85 inch, greater than 0.90 inch, greater than 0.95 inch, or greater than 1.0 inch. 3D printing the faceplate 114 and forming the entire casing 130 out of high-strength faceplate material allows the offset distance OD to be reduced, which, as discussed in Example 2 below, improves ball speed and spin rate.

[0083] The front wall 132 comprises a front wall thickness FWT, as best illustrated in FIG. 9, measured as the distance between front wall front surface 134 and the front wall rear surface 136. As mentioned above, the front wall thickness FWT can be selected to increase strike face deflection without compromising durability. Specifically, the front wall thickness FWT can be increased to decrease strike face deflection but increase durability. Decreasing the front wall thickness FWT increases strike face deflection but potentially decreases durability. Reinforcing the casing 130 with high-strength material, as described herein, allows the front wall thickness FWT to be reduced while maintaining durability. In many embodiments, the front wall thickness FWT can be measured within a vertical plane extending through the face center (FC) in a front-to-back direction. In some embodiments, the front wall thickness FWT can be between 0.010 and 0.025 inch, 0.025 and 0.050 inch, 0.050 and 0.075 inch, 0.075 and 0.100 inch, 0.100 and 0.125 inch, 0.125 and 0.150 inch, or between 0.150 and 0.175 inch. In some embodiments, the front wall thickness FWT can be less than 0.175 inch, less than 0.150 inch, less than 0.125 inch, less than 0.100 inch, less than 0.075 inch, less than 0.050 inch, less than 0.025 inch, or less than 0.010 inch.

[0084] In some embodiments, the IRM further comprises an insert 170 disposed within the aperture 140 and formed of a flexible, polymeric material. The insert 170, as best illustrated in FIG. 10, closes off the aperture 140 to prevent migration of debris into the interior chamber and can impact the performance of the IRM and durability of the club head. The insert 170 is configured to engage the casing walls, thereby securing the insert 170 within the casing 130. The material composition, overall construction, inclusion of hybrid materials, and geometry of the insert 170 can affect the overall performance (bending, retraction rate, reactivity to force) of the IRM. The insert 170 and the casing 130 can comprise complementary geometries that provide durability and mechanically interlock or otherwise fit and secure the insert 170 within the casing 130, even after repeated, violent impacts. In some embodiments, the insert 170 entirely fills the aperture 140 with solid material between the casing front wall 132 and the casing rear wall 142. In some embodiments, the insert 170 can be hollowed out or provided with some other suitable geometry that creates a gap 171 or channel within the insert 170, as illustrated in FIG. 10.IV. Impact Response Modulator with High-Strength Material Reinforcement

[0085] As described above, the high-strength faceplate forms the entire casing and aperture, as well as one or more returns. The high-strength faceplate material reinforces the casing, increasing strike face deflection without compromising durability. Specifically, design choices that increase strike face deflection, such as modifying the front wall offset, the casing length, the front wall height front wall, or the front wall thickness, can be implemented without exceeding the yield strength of the faceplate material, thereby maintaining durability.

[0086] The faceplate 114 comprises a sole return 116 that forms the entire casing 130. The faceplate 114 can optionally include one or more additional returns that are used in combination with the IRM 120 to increase strike face deflection. The returns (including the sole return 116) are regions of the faceplate 114 that wrap over the strike face perimeter and form other forward regions of the club head 100, such as forward regions of the crown 110, sole 112, heel 104, or toe 106. The returns replace these areas of the club head 100 that typically experience high impact stresses and would otherwise be formed of the body material with the high-strength faceplate material. Thus, the thickness of these areas of the club head 100 can be reduced without sacrificing durability, thereby increasing strike face deflection. Additionally, the returns can place weld lines away from the strike face 102, on the crown 110, heel 104, or toe 106, respectively. Doing so removes any potential hindrance in strike face deflection caused by the weld beads.

[0087] The one or more returns can be described in relation to the faceplate perimeter 155, which is the outermost edge of the faceplate 114 that couples to the body 101 and / or other club head components. Referring to FIG. 2, the faceplate 114 comprises a sole return 116 that wraps over the leading edge 103 and forms the forward sole region 166 as well as the entire casing 130 and aperture 140. As such, the faceplate bottom edge 157 is located on the sole 112 and not on the strike face 102. As discussed in further detail below, the sole return 116 forms the entire casing 130. In some embodiments, referring to FIG. 1, the faceplate 114 comprises a crown return 115 that wraps over the transition from the strike face 102 to the crown 110, thereby forming a forward portion of the crown 110 In embodiments comprising a crown return 115, the faceplate top edge 160 is located on the crown 110 and not on the strike face 102. Similarly, in other embodiments such as that illustrated in FIG. 2, the faceplate 114 can comprise a toe return 161, wrapping over the transition between the strike face 102 and the toe 106, thereby forming a forward portion of the toe 106. In embodiments comprising a toe return 161, the faceplate toe edge 159 is located on the toe 106 and not on the strike face 102. In other embodiments, the faceplate 114 comprises a heel return (discussed in further detail below) that wraps over the transition between the strike face 102 and the heel 104, thereby forming a forward portion of the heel 104, wherein the faceplate heel edge 158 is located on the heel 104 and not on the strike face 102. The faceplates described herein can comprise a crown return, a heel return, a toe return, or any combination thereof. In some embodiments, the faceplate 114 is a monolithic component that comprises a sole return 116 integrally forming the entire casing 130 and aperture 140, a crown return 115, and a toe return 161. Specific return combinations and configurations are discussed in detail below.A. Faceplate Integrally Forming the Casing

[0088] As discussed above, the faceplate integrally forms the entire casing. The casing is therefore formed of high-strength material the improves club head durability. As discussed above, the faceplate is a monolithic, high-strength component that can form one or more returns. Referring to FIG. 11, the faceplate 214 comprises a sole return 216 that extends rearward from the bottom of the strike face 202 and forms a forward region of the sole 212. The faceplate 214, therefore, forms at least a portion of the strike face 202 and wraps around the leading edge 203 to form the forward region of the sole 212. The sole return 216 integrally forms the entire casing 230, including the entire casing front wall 232 and the entire casing rear wall 242. Accordingly, the faceplate 214 the entire aperture 240 is formed within the sole return 216. The faceplate 214, the casing 230, and the aperture 240 are integrally formed in a single, monolithic component. In the illustrated embodiment, the body 201 forms no portion of the casing 230 and no portion of the aperture 240.

[0089] The faceplate is formed through an additive manufacturing process, such as 3D printing, metal injection molding, casting, or any other suitable forming method that provides high-strength faceplate material with complex geometries. The faceplate comprises a complex geometry including the sole return and the various casing walls. As described above, the casing walls are separated from the strike face by a forward sole region. This configuration improves durability but adds additional bends to the faceplate, resulting in a more complex geometry.

[0090] The faceplate can be formed through various additive manufacturing (AM) processes, including but not limited to Powder Bed Fusion (PBF) methods such as Selective Laser Melting (SLM), Electron Beam Melting (EBM), and Direct Metal Laser Sintering (DMLS), Binder Jetting, Directed Energy Deposition (DED) techniques, such as Laser Metal Deposition (LMD) or Electron Beam Additive Manufacturing (EBAM). In each method, post-processing steps, including heat treatment, hot isostatic pressing (HIP), CNC machining, and surface treatments such as shot peening, polishing, or coating application, may be utilized to achieve desired mechanical properties, durability, or performance.

[0091] In one embodiment, the 3D printed faceplate is formed through Selective Laser Melting (SLM) that uses a high-powered laser to fully melt and fuse metallic powders layer by layer to create complex, high-density 3D parts directly from a digital model. The process begins with a thin layer of metal powder being spread across a build platform inside a sealed chamber, often filled with inert gas like argon to prevent oxidation. A fiber laser then selectively scans and melts the powder according to the cross-section of the part from the digital CAD file. Once a layer is complete, the build platform lowers by one layer thickness, and a new layer of powder is spread, repeating the process until the part is fully built. Post-processing steps such as support removal, heat treatment, and surface finishing may be required to achieve the desired mechanical properties and dimensional accuracy.

[0092] The metallic powder used in the SLM process plays a critical role in the quality and purity (lacking impurities) of the final part. The metallic powder has several parameters such as sphericity, fluidity, grain size, and chemistry that can be adjusted to reduce failures of the final formed part. Common failures of 3D printed parts results from an increase in Aluminum Oxide Particles, high porosity, high percent humidity and clump, and / or inconsistent grain size, which all result in localized stress risers, resulting in micro-fractures, increased slip planes, and / or critical cracks. Furthermore, the metallic powder may become contaminated if a reclamation tank is used during the SLM process which also increases the chance of failure of the final part.

[0093] In one embodiment of a 3D printed faceplate, the faceplate is formed by an SLM process using a C300 metallic powder. The C300 powder comprises a chemistry composition of Carbon (C)≤0.03%; Silicon (Si)≤0.1%; Sulfur(S)≤0.01%; Phosphorus (P)≤0.01%; Manganese (Mn)≤0.1%; Nickel (Ni) within the range of 18-19%; Molybdenum (Mo) within the range of 4.6-5.2%; Titanium (Ti) within the range of 0.5-0.8%; Aluminum (Al) within the range of 0.05-0.15%; and Cobalt (Co) within the range of 8.5-9.5%.

[0094] In another embodiment of a 3D printed faceplate formed from a C300 metallic powder, the metallic powder comprises similar percentages as described above, except the Aluminum (Al) is within the range of 0.02-0.04%. The lower Aluminum (Al) amount will help reduce the amount Al-Oxide particles in the final part, thereby improving the mechanical properties and durability of the final IRM formed from 3D printing.

[0095] In one embodiment of a 3D printed faceplate formed from a C300 metallic powder having the chemistry described above further comprises various physical properties to improve the quality of the final IRM. The C300 powder comprises a D10 grain size ranging from 16-23 μm, a D50 grain size ranging from 30-40 μm, a D90 grain size ranging from 50-60 μm, a fluidity that is less than or equal to 20s / 50 g, and a sphericity greater than or equal to 90%. The D10 grain size is the diameter of particles that 10% of the particles are smaller than. The D50 grain size is the diameter of the particles that 50% of the particles are smaller than. The D90 grain size is the diameter of particles that 90% of the particles are smaller than. It is important to have a varied grain size, as described above, to reduce porosity in the powder and increase packing density.

[0096] In other embodiments, the D10 grain size can range from 5-30 μm. For example, the D10 grain size can range from 5-10 μm, 10-15 μm, 15-20 μm, 20-25 μm, or from 25-30 μm. In other embodiments, the D50 grain size can range from 20-50 μm. For example, the D50 grain size can range from 20-30 μm, 30-40 μm, or from 40-50 μm. In other embodiments, the D90 grain size can range from 30-70 μm. For example, the D90 grain size can range from 30-40 μm, 40-50 μm, 50-60 μm, or from 60-70 μm.

[0097] In another embodiment of a 3D printed faceplate formed from a C300 metallic powder, the powder comprises a fluidity that is greater than or equal to 25s / 50 g, and a sphericity greater than or equal to 95%. The increased sphericity can improve the flowability of the powder resulting in a more consistent and uniform layer deposition. Furthermore, the sphericity can increase the packing density of the powder that reduces porosity in the final part thereby improving mechanical properties.

[0098] The final faceplate formed from 3D printing using a high strength metallic powder can be post-processed using various heat treating methods as desired to achieve desired mechanical properties.

[0099] In other embodiments, the 3D printed faceplate formed from other high-strength steel alloy powders, for example, but not limited to Carpenter 455, Carpenter 475, HT1770, M455 (H900), M475 (H975), 4140, 4340, C300, C350, 6150 steel, K301, Carpenter 158, Carpenter 450, Carpenter 465, Carpenter 431, Inconel 718, Aermet 100, Maraging Steel (MSL 350, MSL 450), H13 Tool Steel, 17-4 PH Stainless Steel, 18Ni (300M), S7 Tool Steel, D2 Tool Steel, 440C Stainless Steel, SKD11, SAE 9260, 10B21 Boron Steel, 52100 Steel, Tungsten Carbide Steel, Viking 80, or 4130 Chromoly Steel.

[0100] The laser parameters of the SLM process, or other additive manufacturing process, can be adjusted to improve the 3D printing process. The parameters that can be adjusted are focal length, defocus length, focal spot size, defocus spot size, laser power, scan speed, scan pitch, scan thickness, and filling method.

[0101] The faceplate 214 comprises a faceplate perimeter 255 that is continuously coupled to the body 201, such that there are no unattached faceplate edges. In some embodiments, the faceplate perimeter 255 is continuously welded to the body 201. The faceplate perimeter 255 can comprise a sole return rear edge 257 coupled to the body 201 along the sole 212. The sole return rear edge 257 is located rearward of the casing rear wall 242 and rearward of the aperture 240. Referring to FIG. 11, the sole return rear edge 257 can be spaced rearward from the aperture 240 by a rear sole return length LRs. A sufficient rear sole return length LRs enables the sole return rear edge 257 to be welded to the body 201 without the heat from the welding process damaging the casing walls. In some embodiments, the rear sole return length LRs can be between 0.05 and 0.25 inch. In some embodiments, the sole return length LRs can be between 0.05 and 0.10 inch, between 0.10 and 0.15 inch, between 0.15 and 0.20 inch, or between 0.20 and 0.25 inch. In some embodiments, the sole return length LRs can be greater than 0.05 inch, greater than 0.10 inch, greater than 0.15 inch, greater than 0.20 inch, or greater than 0.25 inch.

[0102] In some embodiments, the faceplate 214 forms an “L-cup” configuration, as best illustrated in FIG. 11. In this configuration, the faceplate 214 forms at least a portion of the strike face 202 and comprises a sole return 216 forming at least a portion of the sole 212. The sole return 216 forms the entire casing 230 the entire aperture 240. The sole return 216 thereby increases strike face deflection by reinforcing the casing 230 with high-strength faceplate material. The L-cup faceplate 214 can be devoid of a crown return, a toe return, or a heel return. In such embodiments, the faceplate heel edge 258, the faceplate toe edge 259, and the faceplate top edge 260 are all located on the strike face 202.

[0103] In some embodiments, the 3D printed faceplate 314 is a “cup face” configuration that includes a crown return 315, a toe return 361, and a sole return 316 that entirely forms the casing 330, as best illustrated in FIGS. 12 and 13. This faceplate configuration greatly increases strike face deflection by forming and reinforcing a portion of the crown 310 and a portion of the toe 306 with high-strength faceplate material. The inclusion of the crown return 315 and the toe return 361, in addition to the sole return 316, improve strike face deflection while retaining durability. Specifically, the crown return 315 increases durability and performance by reinforcing (via the high-strength faceplate material) the transition between the strike face 302 and the crown 310 and forward portions of the crown 310, which are both areas that experience impact stresses. Similarly, the toe return 361 increases durability and performance by reinforcing the transition between the strike face 302 and the toe 306. The IRM 320, the crown return 315, and the toe return 361 cooperate to increase strike face deflection without sacrificing durability. In particular, the IRM 320 increases sole flexibility, the crown return 315 increases crown flexibility, and the toe return 361 increases toe flexibility. Further, as discussed above, the sole return 316, the crown return 315, and the toe return 361 increase strike face deflection by separating the sole return rear edge 357, the faceplate top edge 360, and the faceplate toe edge 359 from the strike face 302, which removes any potential hindrance to strike face deflection caused by weld beads.

[0104] The IRM 320 delofts the strike face 302 at impact, thereby reducing stress in the crown 310 and allowing the thickness of the crown 310 to be reduced without sacrificing durability. In some embodiments, as shown in FIGS. 14 and 15, the crown return 315 further comprises an indent 341. The indent 341 is recessed into an interior surface of the crown return 315. The indent 341 is a region of reduced thickness relative to the remainder the crown return 315. In the illustrated embodiment, the indent 341 is isolated within the crown return 315, such that the indent perimeter 394 is located entirely within the bounds of the crown return 315. The indent 341 increases strike face deflection without compromising faceplate durability. The indent 341 can increase ball speed by upwards of 0.5 mph (without compromising durability) over a club head comprising a crown return without an indent. Specifically, the indent 341 strategically weakens the forward portion of the crown 310, thereby increasing the amount the crown 310 deflects upward at impact. This increased upward crown deflection in turn increases the amount of strike face deflection. Because the indent 341 is isolated within the crown return 315, this additional deflection can occur without exceeding the yield strength of the faceplate material.

[0105] The indent 341 comprises an indent thickness TI that is reduced in comparison to the crown return thickness TCR. In some embodiments, the indent thickness TI can be between 0.005 and 0.020 inch, whereas the crown return thickness TCR can be between 0.020 and 0.050 inch. In some embodiments, the indent thickness TI can be less than 0.020 inch, less than 0.015 inch, or less than 0.010 inch. Further, the crown return 315 can comprise an indent thickness ratio TI / TCR defined as the indent thickness TI divided by the crown return thickness TCR. In some embodiments, the indent thickness ratio TI / TCR can be less than 0.5, less than 0.4, less than 0.3, less than 0.2, or less than 0.1.

[0106] In the illustrated embodiment, the indent 341 is located approximately in the center of the crown return 315 and extends in a generally heel-to-toe direction. In other embodiments, the indent 341 can be offset towards the toe 306 or towards the heel 304. In the illustrated embodiment, the indent 341 has an approximately rectangular shape. In other embodiments, the indent 341 can have other shapes such as an elongated oval or an arcuate shape.

[0107] The cup face faceplate 314 is readily manufacturable through 3D printing or other various additive manufacturing processes. The cup-face faceplate 314 with a sole return 316 that integrally forms the entire casing 330 and aperture 340 has a complex geometry with more than two bends within a given cross-section. For example, in a vertical cross-section, referring to FIG. 13, the faceplate 314 comprises a bend at the juncture between the front wall 332 and the forward sole region 366, another bend at the juncture between the forward sole region 366 and the strike face 302, and another bend at the juncture between the strike face 302 and the crown return 315. As such, this configuration is not readily manufacturable by forging or forming. Therefore, it is advantageous to manufacture said faceplate via 3D printing or another suitable additive manufacturing process.

[0108] In some embodiments, the casing 330 can comprise one or more end reinforcements 326 that dissipate stress within the casing 330. The end reinforcements 326 can be regions of the sole 312 having increased thickness that surround one or more of the casing walls. The end reinforcements 326 are concentrations of club head mass with a substantially greater thickness than the surrounding casing walls. In addition to integrally forming the casing walls, the faceplate 314 can also form the end reinforcement(s) 326, as illustrated in FIG. 12. The high-strength faceplate material combines with the end reinforcement(s) to reduce stress near the casing heel wall 352 or the casing toe wall 354. Further, in some embodiments, the high-strength faceplate material allows the thickness of the end reinforcements to be reduced without exceeding the faceplate material's yield strength, thereby increasing strike face deflection and creating discretionary mass. In the illustrated embodiment, the sole return 316 forms a toe end reinforcement 326 located near the casing toe wall 354. In other embodiments, the sole return 316 can form a heel end reinforcement located near the casing heel wall 352 instead of, or in addition to, the toe end reinforcement 326. Although the end reinforcement(s) 326 are concentrations of club head mass located on the casing walls, their location towards the heel wall 352 and or / the toe wall 354 does not hinder strike face deflection. In the illustrated embodiment, the end reinforcement(s) 326 can be generally circular in shape. In other embodiments, the end reinforcement(s) can be any suitable shape for reducing stress near the heel wall 352 or the toe wall 354.

[0109] The end reinforcement(s) can each comprise a thickness (i.e., a heel end reinforcement thickness or a toe end reinforcement thickness) measured from the aperture 140 to the opposing surface of the end reinforcement. As discussed above, the end reinforcement(s) can have substantially larger thicknesses than the remainder of the casing walls. Specifically, in some embodiments, the heel end reinforcement thickness and / or the toe end reinforcement thickness can be at least 50% greater, 75% greater, 100% greater, 150% greater, 200% greater, or 300% greater than the front wall thickness FWT.

[0110] The 3D printed faceplates described herein can comprise more complex or exotic wall designs that are difficult or impossible to form by alternative methods such as forging or forming. The faceplates comprising these exotic wall geometries, described below, can improve strike face flexibility without sacrificing durability over simpler faceplate designs. The wall geometries may include severe draft angles, undercuts, and multiple bends within a given cross-section that are not suitable to be forged or formed. However, because these faceplates can be 3D printed, the manufacturing constraints associated with forging and forming can be circumvented. For example, for the 3D printed faceplate, there is no need for sufficient draft angle clearance to remove a forging or forming tool.

[0111] The 3D printed faceplate 414 can comprise one or more front wall steps 480 that increase the flexibility of the front wall 432 while maintaining durability. As best illustrated in FIG. 16, the front wall step 480 is a localized region of the front wall 432 having a smaller thickness than the surrounding area of the front wall 432 to increase strike face deflection, create discretionary mass, and maintain durability. The front wall 432 further comprises a ledge 481 that is substantially perpendicular to the front wall front surface 434 and creates an abrupt change in thickness between the front wall step 480 and the remainder of the front wall 432. In some embodiments, the front wall step 480 is located at or near the front wall top surface 438. In some embodiments, as illustrated in FIG. 16, the front wall step 480 forms the entire front wall top surface 438. In some embodiments, the faceplate 414 forms a single, elongate front wall step 480. In other embodiments, the faceplate can comprise multiple discrete front wall steps that are spaced intermittently along the front wall 432.

[0112] The front wall step 480 can be thinner than the surrounding areas of the front wall 432. The front wall step 480 thins the front wall 432 to increase strike face flexibility while retaining durability. The front wall step 480 draws impact stress away from the front wall base 433, where such stress commonly concentrates. A thin front wall step 480 improves strike face deflection, because as evidenced below in Example 2, a reduced front wall thickness FWT improves ball speed and spin rate. In some embodiments, the front wall thickness FWT measured at the front wall step 480 can be significantly lower than the maximum front wall thickness FWT. In some embodiments, the maximum front wall thickness FWT can be greater than 0.100 inch, whereas the front wall thickness FWT at the front wall step 480 can be less than 0.075 inch. In some embodiments, the front wall thickness FWT at the front wall step 480 can be less than 0.070 inch, less than 0.065 inch, less than 0.060 inch, less than 0.055 inch, less than 0.050 inch, less than 0.045 inch, less than 0.040 inch, less than 0.035 inch, less than 0.030 inch, less than 0.025 inch, or less than 0.020 inch.

[0113] In some embodiments the faceplate 414 can comprise a rear wall step instead of or in addition to the front wall step 480. The rear wall step can be substantially similar to the front wall step 480, other than that the rear wall step is formed in the rear wall 442 rather than the front wall 432.

[0114] The faceplate 414 comprising a front wall step 480 is readily manufacturable through 3D printing or other various additive manufacturing processes. The front wall thickness FWT at the front wall step 480 may be less than the minimum thickness requirement for a typical forming or forging process. As such, this configuration is not readily manufacturable by forging or forming. Typical 3D printing or additive manufacturing processes often do not have such minimum thickness requirements. Further, because the front wall 432 is spaced from the strike face 402 by the forward sole region 466, combining the front wall 432 having a front wall step 480 with a crown return would create three bends in the vertical cross-section, making such a design unsuitable for forging or forming. Therefore, it is advantageous to manufacture the faceplate 414 via 3D printing or another suitable additive manufacturing process.

[0115] The 3D printed faceplate 514 can comprise one or more casing wall undercuts that thin strategic portions of the front wall 532 to increase strike face deflection and create discretionary mass, all while retaining durability. As best illustrated in FIG. 17, the front wall undercut 580 is an elongate recess formed into the front wall front surface 534. The front wall undercut 580 can extend substantially horizontally along the length of the front wall 532. The front wall undercut 580 comprises an undercut base 581 that is inset relative to the front wall front surface 534. The front wall thickness FWT at the front wall undercut 580, which is defined by the distance between the undercut base 581 and the front wall rear surface 536, can be less than the remaining front wall thickness FWT. In some embodiments, the maximum front wall thickness FWT can be greater than 0.100, whereas the front wall thickness FWT at the front wall undercut 580 can be less than 0.075 inch. In some embodiments, the front wall thickness FWT at the front wall undercut 580 can be less than 0.070 inch, less than 0.065 inch, less than 0.060 inch, less than 0.055 inch, less than 0.050 inch, less than 0.045 inch, less than 0.040 inch, less than 0.035 inch, less than 0.030 inch, less than 0.025 inch, or less than 0.020 inch.

[0116] The front wall undercut 580 is spaced between the front wall top surface 538 and the front wall base 533. This configuration thins the middle of the front wall 532 to promote strike face deflection. Stress typically tends to concentrate near the front wall top surface 538 and the front wall base 533 rather than the middle of the front wall 532, thinning this portion of the front wall 532 increases deflection without compromising durability.

[0117] In some embodiments, the front wall undercut 580 can be recessed into the front wall rear surface 536 rather than the front wall front surface 534. Further, in some embodiments the faceplate 514 can comprise a rear wall undercut instead of or in addition to the front wall undercut 580. The rear wall undercut can be substantially similar to the front wall undercut 580, but that the rear wall undercut is recessed into a surface of the rear wall 542 rather than the front wall 532.

[0118] The faceplate 514 comprising a front wall undercut 580 is readily manufacturable through 3D printing or other various additive manufacturing processes. In some embodiments, the front wall undercut 580 can be implemented in a “cup-face” faceplate that includes at least a sole return that forms the entire casing, a crown return, and a toe return. The cup-face faceplate comprising a front wall undercut 580 has a complex geometry with several bends within a given cross-section. As illustrated in FIG. 17, the front wall 532 is separated from the strike face 502 by the forward sole region 566, which adds to the total number of bends in the faceplate 514. For example, in a vertical cross-section, the faceplate comprises one or more bends forming the undercut into the front wall, another bend at the juncture between the front wall and the sole, another bend at the juncture between the sole and the strike face, and another bend between the strike face and the crown return. As such, this configuration is not readily manufacturable by forging or forming. Therefore, it is advantageous to manufacture said faceplate via 3D printing or another suitable additive manufacturing process.

[0119] The 3D printed faceplate 614 can comprise one or more casing wall cavities that increase strike face deflection and create discretionary mass, all while retaining durability. In some embodiments, the front wall 632 comprises a front wall cavity 680, as best illustrated in FIG. 18. The front wall cavity 680 is a hollowed-out portion of the front wall 632. The front wall cavity 680 is a hollow cavity or chamber that is completely encapsulated within the front wall 632. The front wall cavity 680 can be an elongate cavity that extends substantially horizontally along the length of the front wall 632. In some embodiments, the front wall 632 comprises a single, continuous front wall cavity 680 extending along a portion of the front wall 632. In other embodiments, the front wall 632 can comprise a plurality of discrete front wall cavities that are separated from one another within the front wall 632.

[0120] In some embodiments the faceplate 614 can comprise a rear wall cavity instead of or in addition to the front wall cavity 680. The rear wall cavity can be substantially similar to the front wall cavity 680, but that the rear wall cavity is encapsulated within the rear wall 642 rather than the front wall 632.

[0121] The faceplate 614 comprising a front wall cavity 680 is readily manufacturable through 3D printing or other various additive manufacturing processes. In some embodiments, the front wall cavity 680 can be implemented in a “cup-face” faceplate that includes at least a sole return that forms the entire casing, a crown return, and a toe return. The hollow nature of the front wall cavity 680, whereby the front wall cavity is entirely surrounded by the high-strength faceplate material is not readily manufacturable by forging or forming. Further, because the front wall 632 is spaced from the strike face 602 by the forward sole region 666, combining the front wall 632 having a front wall cavity 680 with a crown return would create three bends in the vertical cross-section, making such a design unsuitable for forging or forming. Therefore, it is advantageous to manufacture the faceplate 614 via 3D printing or another suitable additive manufacturing process.

[0122] The 3D printed faceplate 714 can comprise one or more crossbeams that reinforce and stiffen the front wall 732. The crossbeams can allow the remainder of the front wall 732 to be thinned without compromising durability, thereby increasing strike face deflection. In some embodiments, the front wall 732 comprises a front wall crossbeam 780, as best illustrated in FIG. 19. The front wall 732 includes a stem 781 and the front wall crossbeam 780. The stem 781 extends upward from the front wall base 733. The front wall crossbeam 780 is located at the top of stem 781 and extends transverse to the stem 781. The front wall crossbeam 780 comprises a front end 782 that juts forward of the front wall front surface 734 and overhangs at least a portion of the forward sole region 766. As such, the front end 782, the stem 781, and the forward sole region 766 collectively define an undercut. The front wall crossbeam 780 further comprises a rear end 784 that juts rearward of the front wall rear surface 736 and overhangs at least a portion of the aperture 740. Further, the front wall crossbeam 780 can be elongated in a substantially heel-to-toe direction along the length of the front wall 732.

[0123] The front wall crossbeam 780 stiffens the front wall 732 without adding a significant amount of mass. The front wall crossbeam 780 creates an “I-beam” configuration wherein the forward sole region 766 and the front wall crossbeam 780 function like the flanges of an I-beam, and the stem 781 functions like the web of an I-beam. This increase rigidity increases front wall durability and thereby allows the stem 781 to be thinned without risk of failure. In some embodiments, the stem 781 comprises a stem thickness tST less than 0.100 inch. In some embodiments, the stem thickness tST can be less than 0.095 inch, less than 0.090 inch, less than 0.085 inch, less than 0.080 inch, less than 0.075 inch, less than 0.070 inch, less than 0.065 inch, less than 0.060 inch, less than 0.055 inch, or less than 0.050 inch. Thinning the stem 781 increases strike face deflection. Further, in some embodiments the faceplate 714 can comprise a rear wall crossbeam instead of or in addition to the front wall crossbeam 780. The rear wall crossbeam can be substantially similar to the front wall crossbeam 780, but that the rear wall crossbeam is disposed on top of the rear wall 742 rather than the front wall 732.

[0124] The faceplate 714 comprising a front wall crossbeam 780 is readily manufacturable through 3D printing or other various additive manufacturing processes. In some embodiments, the front wall crossbeam 780 can be implemented in a “cup-face” faceplate that includes at least a sole return that forms the entire casing, a crown return, and a toe return. This configuration improves strike face deflection by increasing the flexibility of the casing front wall 732 via the crossbeam 780, the flexibility of the crown via the crown return, and the flexibility of the toe via the toe return (as described above). The cup-face faceplate comprising a front wall crossbeam 780 has a complex geometry with several bends within a given cross-section. For example, in a vertical cross-section, the faceplate comprises a bend at the juncture between the crossbeam front end 782 and the stem 781, another bend at the juncture between the stem 781 and the sole 712, another bend at the juncture between the sole 712 and the strike face 702, and another bend at the juncture between the strike face 702 and the crown return. As such, this configuration is not readily manufacturable by forging or forming. Therefore, it is advantageous to manufacture said faceplate via 3D printing or another suitable additive manufacturing process.

[0125] In some embodiments, the faceplate 914 can comprise a heel return 962 forming part or all of the hosel 905. In some embodiments, the faceplate 914 can comprise a “360-degree cup face” whereby the faceplate 914 integrally forms the strike face 902, a sole return 916 forming the entire casing 930, a crown return 915, a toe return 961, and a heel return 962 including the entire hosel 905 all in a single, monolithic piece.

[0126] In the 360-degree cup face, the faceplate perimeter edge 955 extends circumferentially around the entire club head 900 such that no portion of the faceplate perimeter edge 955 is located on the strike face 902, as best illustrated in FIGS. 20 and 21. More specifically, the sole return rear edge 957 is located on the sole 912, the faceplate heel edge 958 is located on the heel 904, rearward of the entire hosel 905, the faceplate toe edge 959 is located on the toe 906, and the faceplate top edge 960 is located on the crown 910. This configuration improves manufacturability by simplifying the weld path and welding process and removing any weld lines on the strike face 902. Removing the weld lines from the strike face 902 also prevents any potential hindrance in strike face deflection caused by weld beads. Further, the 360-degree cup face faceplate 914 increases high-strength material coverage near the strike face 902, in the casing 930, and in forward portions of the crown 910, sole 912, heel 904, and toe 906, where the highest impact stresses occur. Maximizing high-strength material coverage in this way allows the thickness of various regions of the crown 910, the sole 912, the heel 904, the toe 906, and the hosel 905 to be reduced while maintaining durability. This increases the overall flexibility of the club head, thereby resulting in more internal energy at impact and increasing strike face deflection.

[0127] In some embodiments, the 360-degree cup face faceplate 914 integrally forms the entire hosel 905, including the hosel top end. The 360-degree cup face faceplate 914 is readily manufacturable through 3D printing or other various additive manufacturing processes. The 360-degree cup face faceplate 914 has a complex geometry with more than two bends within a given cross-section, similar to the cup face faceplate 414 described above. For example, in a vertical cross-section, the 360-degree cup face faceplate 914 comprises a bend at the juncture between the casing front wall and the sole 912, another bend at the juncture between the sole 912 and the strike face 902, and another bend between the strike face 902 and the crown return 915. Further, the hosel geometry adds an extra layer of complexity to the faceplate 914 that complicates manufacture. As such, this configuration is not readily manufacturable by forging or forming. Therefore, it is advantageous to manufacture said faceplate via 3D printing or another suitable additive manufacturing process.EXAMPLESA. Example 1—Ball Flight Performance of Golf Club Head with IRM

[0128] The ball flight performance characteristics of an exemplary fairway-wood type club head comprising an Impact Response Modulator (IRM) were compared to those of a control club head without an IRM. The exemplary club head comprised a reverse L-cup faceplate with a crown return, but no sole return. The exemplary IRM included a casing formed by the body. The casing included a toe relief and formed an aperture that received a polymeric insert. The IRM allowed the sole to bend at impact, thereby increasing strike face deflection and delofting the strike face. The control club head was substantially similar to the exemplary club head but was devoid of an Impact Response Modulator entirely.

[0129] Various ball flight characteristics, including ball speed, launch angle, and spin rate, were determined via a player test. The player test involved 19 golfers hitting a representative number of golf shots with the exemplary club head and the control club head. The ball flight results of the player test are displayed in Table 1 below.TABLE 1Player Test Ball Flight CharacteristicsLaunchCarryBall SpeedAngleSpin RateDistanceClub Head(mph)(degrees)(rpm)yardsExemplary155.510.43547252.1Control154.510.33911248.7

[0130] As displayed in Table 1 above, the exemplary club head exhibited an increase in ball speed of 1.0 mph and a decrease in spin rate of 364 rpm in comparison to the control club head, with a similar launch angle. The decreased spin rate created a more piercing ball flight that cuts through the air and travels further. These improved ball flight characteristics increased carry distance by 3.4 yards on average.

[0131] In addition to the performance results obtained through player testing, robotic testing was used to compare ball flight characteristics between the exemplary club head and the control club head. A robotic swing apparatus tested both club heads at various locations along the strike face, including the face center (FC), and three “low” locations respectively located at 0.1 inch, 0.2 inch, and 0.3 inch below the face center (FC). Table 3 displays the results of the robotic testing at each location, as well as the averages over all locations.TABLE 2Robotic Testing Ball Flight CharacteristicsBall SpeedSpin RateCarry DistanceClub HeadLocation(mph)(rpm)(yards)ExemplaryFace Center151.93203249.00.1 inch low151.63383244.00.2 inch low150.63265235.40.3 inch low150.73070221.3Average151.23230237.4ControlFace Center150.53714240.00.1 inch low149.83916237.70.2 inch low149.43835231.30.3 inch low149.83543220.2Average149.93752232.3

[0132] At the face center (FC), the exemplary club head exhibited an increase in ball speed of 1.4 mph and a decrease in spin of 511 rpm, which creates a more piercing ball flight that cuts through the air and travels further. These improvements resulted in an increase in carry distance of 9.0 yards. On average across all locations, the exemplary club head exhibited an increase in ball speed of 1.3 mph and a decrease in spin of 522 rpm in comparison to the control club head, resulting in an increase in carry distance of 5.1 yards. Overall, results of both the player test and the robotic test illustrate the benefits of the IRM. Although the IRM of the exemplary club head was not formed by a high-strength faceplate material, the comparative tests illustrate the general efficacy of the IRM in comparison to a club head without an IRM. The IRM increased strike face deflection in the exemplary club head, which improved ball speed, spin rate, and distance. As discussed above, performance can be further improved through high-strength reinforcement of the casing. The 3D printed faceplate with a sole return that integrally forms the entire casing and aperture can further improve performance by allowing casing length to be increased and wall height and thickness to be reduced and by providing complex geometries that increase strike face deflection but are not readily manufacturable via casting, forging, or forming.B. Example 2—Ball Flight Performance of IRM with High-Strength Material Reinforcement

[0133] The ball flight performance characteristics of an exemplary club head comprising an Impact Response Modulator with a casing reinforced by high-strength material were compared to those of a control club head comprising an Impact Response Modulator with a casing formed by the body material. The exemplary club head comprised a high-strength faceplate and a separate high-strength component located on the sole and forming the entire casing, which allowed for reduced casing wall heights and decreased offset distance between the casing front wall and the strike face while maintaining durability. The control club head comprised an Impact Response Modulator with a casing formed by body material, which required increased casing wall heights and a greater offset distance to maintain structural integrity. The control club head had a front wall height FWH of 0.274 inch, whereas the exemplary club head had a reduced front wall height FWH of 0.192 inch due to the high-strength material reinforcement. The offset distance OD from the casing front wall to the strike face in the control club head was 0.24 inch, whereas the exemplary club head had a reduced offset distance OD of 0.177 inch. The reduced front wall height FWH and offset distance OD each increase the amount the casing bends at impact, thereby increasing strike face deflection.

[0134] Various ball flight characteristics, including ball speed, launch angle, and spin rate, were determined via Finite Element Analysis (FEA) simulations. The analysis simulated center strikes at 115 mph club head speed. The results are displayed in Table 3 below.TABLE 3Ball Flight CharacteristicsLaunchBall SpeedAngleSpin RateClub Head(mph)(degrees)(rpm)Exemplary144.711.552532Control141.511.42919

[0135] As displayed in Table 3 above, the exemplary club head exhibited an increase in ball speed of 3.2 mph compared, a decrease in spin rate of 387 rpm, and similar launch angle. The high-strength IRM component allowed the casing walls to be shortened and moved closer to the strike face, thereby increasing strike face deflection. Although the casing was not integrally formed with the faceplate, the example demonstrates that reinforcing the casing with a high-strength component results in measurable performance benefits. Physical testing (i.e., player testing and robotic testing) will be conducted on prototypes corresponding to the embodiments described herein, which include 3D printed faceplates having sole returns that integrally form the entire casing. Similar ball speed and spin rate improvements are expected for the exemplary club head.C. Example 3—Durability Performance of Club Head Comprising IRM Spaced Rearwardly from Strike Face

[0136] The durability performance characteristics of an exemplary club head comprising an Impact Response Modulator spaced rearwardly from the strike face were compared to those of a control club head comprising an Impact Response Modulator positioned directly adjacent to the strike face of the club head. The exemplary club head, as shown in FIGS. 22-24, comprised a 3D printed C300 steel faceplate 1114, including a strike face 1102 and a sole return 1116 that integrally formed the entire casing 1130. The exemplary casing included a front wall 1132 positioned proximate the strike face 1102 yet separated therefrom by a forward sole region 1166 formed by the faceplate. In turn, the combination of the strike face 1102, forward sole region 1166, and front wall 1132 comprised a U-shaped trough when viewed in cross-section. The control club head, as shown in FIGS. 25-27, also included a 3D printed C300 steel faceplate 1214 comprising a sole return 1216 that integrally formed the entire casing 1230. However, the casing 1230 was devoid of forward sole region and a front wall. Instead, the aperture 1240 was positioned directly adjacent to the rear of the strike face.

[0137] Durability characteristics in the strike face and club head body, including maximum structural stress values, were determined via Finite Element Analysis (FEA) simulations. The analysis simulated center strikes at 115 mph club head speed. The results are displayed in Table 4 below.TABLE 4Durability CharacteristicsFace PlateClub HeadStressBody StressClub Head(ksi)(ksi)Exemplary255131.3Control255150

[0138] As displayed in Table 4 above, both the exemplary and control club heads exhibited equivalent face plate stress values approaching the C300 stress yield limit of 263.6 ksi. However, as shown in FIGS. 22 and 23, the maximum stress region 1190 of the exemplary club head is only present in the casing heel wall 1152. In particular, a maximum stress region defines any region that exhibits stress levels within 10 ksi of the material stress yield limit. Because the maximum stress region 1190 is only present in the casing heel wall 1152, only a small area of the casing 1130 is subject to high stresses at impact. Further, the specific heel wall maximum stress region 1190 of the exemplary golf club head is subject to stress under compression. Due to the structure and characteristics of C300 steel, the material can withstand repeated high levels of stress under compression without risks of buckling and fracturing over time. On the other hand, the control club head exhibited multiple maximum stress regions 1290 dispersed over large areas of the strike face 1202 and casing heel 1252 and toe walls 1254, as shown in FIGS. 25 and 26. Such areas of the integrally formed faceplate 1214 and casing 1230 are subject to stress under tension at impact. While strong under compression stresses, C300 steel is weaker and will fracture over time when exposed to repeated high levels of stress under tension. Therefore, the example demonstrates that spacing the casing rearwardly from the strike face via the forward sole region, as demonstrated by the exemplary club head, results in measurable durability benefits in the integrally formed faceplate and casing.

[0139] Additionally, Table 4 displays that the exemplary club head exhibited a decrease in club head body stress of 19.7 ksi compared to the control club head. Further, the exemplary club head does not comprise maximum stress regions within the club head body, as shown in FIG. 24. On the other hand, the control club head exhibits multiple maximum stress regions 1290 dispersed over large areas of the crown 1210 and sole 1212, as shown in FIG. 27. As described above, such areas of the control club head body are subject to stress under tension upon impacting a golf ball and thus, will fracture over time when exposed to repeated high levels of stress under tension. Therefore, the example further demonstrates that spacing the casing rearwardly from the strike face via the forward sole region, as demonstrated by the exemplary club head, results in measurable durability benefits in the club head body.D. Example 4—Ball Flight Performance of Golf Club Head with 3D Printed High-Strength Face Plate

[0140] The ball flight performance characteristics of an exemplary club head comprising a 3D printed high-strength face plate were compared to those of a control club head comprising a forged high-strength face plate. Both the exemplary club head and the control club head comprised an “L-Cup” faceplate forming a strike face and sole return with the same geometries and the same high-strength C300 steel material. The difference between the exemplary club head and the control club head was that the exemplary club head face plate was formed through Selective Laser Melting (SLM) 3D printing process while the control club head had a face plate that formed through conventional forging and forming process.

[0141] Robotic testing was used to compare ball flight characteristics between the exemplary club head and the control club head. A robotic swing apparatus tested face center strikes for both club heads at approximately 103 mph club head speed. Table 5 displays the results of the robotic testing face center strikes.TABLE 5Ball Flight Characteristics, All LocationsCarryBall SpeedSpin RateDistanceClub Head(mph)(rpm)(yards)Exemplary152.03724246.7Control151.63636245.1

[0142] As illustrated by Table 5, the exemplary club head, comprising a 3D printed C300 steel face plate, exhibited comparable ball flight performance characteristics to the control club head, comprising a forged C300 face plate. In particular, the exemplary club head and the control club head exhibited similar ball speeds, spin rates, and carry distances for face center strikes. More specifically, the exemplary club head increased ball speed by 0.4 mph, increased spin rate by 88 rpm, and increased carry distance by 1.6 yards. While the exemplary club head exhibited an increased spin rate of 88 rpm in comparison to the control club head, such a difference is not enough to negatively affect ball flight performance.

[0143] Accordingly, the results of the robotic test illustrate that a club head comprising a 3D printed high-strength face plate produced comparable ball flight performance to a conventionally formed high-strength face plate. As such, a high strength face plate that is formed from 3D printing is effective for performance and can be used as a viable alternative to conventionally formed face plates in terms of ball flight performance. The 3D printed face plates allow complex geometries, such as a casing or an Impact Response Modulator, according to embodiments of the present invention, to be formed in the high-strength faceplate.E. Example 5—Durability Performance of Club Heads with 3D Printed Faceplates

[0144] The durability performance characteristics of a control club head with a 3D printed faceplate was compared to an exemplary club head with a 3D printed faceplate. The control club head and exemplary club head comprised the same geometries and construction except for the faceplate. The faceplate of the control club head was made through Selective Laser Melting (SLM) additive manufacturing process with a control C300 powder. The exemplary club head was also made through SLM additive manufacturing process with an exemplary C300 powder. The control powder had more impurities than the exemplary powder. The exemplary powder comprised chemistry and physical properties similar to the C300 powder described above and according to aspects of the present invention. Specifically the exemplary powder comprised a chemistry of Carbon (C)≤0.03%; Silicon (Si)≤0.1%; Sulfur(S)≤0.01%; Phosphorus (P)≤0.01%; Manganese (Mn)≤0.1%; Nickel (Ni) within the range of 18-19%; Molybdenum (Mo) within the range of 4.6-5.2%; Titanium (Ti) within the range of 0.5-0.8%; Aluminum (Al) within the range of 0.05-0.15%; and Cobalt (Co) within the range of 8.5-9.5%. The exemplary C300 powder further comprised physical properties of a D10 grain size ranging from 16-23 μm, a D50 grain size ranging from 30-40 μm, a D90 grain size ranging from 50-60 μm, a fluidity that is less than or equal to 20s / 50 g, and a sphericity greater than or equal to 90%.

[0145] The durability performance characteristics were determined using an air cannon test that would consistently launch golf balls at the same location on the face with the same speed until failure. The number of shots till failure was recorded for each club head and averaged.TABLE 6Durability ResultsAverage Number ofClub HeadHitsExemplary1225Control1144

[0146] As illustrated in Table 6 above, the Exemplary club head averaged 1225 hits until failure while the control club head only averaged 1144 hits until failures. The exemplary club head averaged 81 hits more than the control club head, and as such, had improved durability performance characteristics over the control club head. The improved exemplary C300 powder used to manufacture the Exemplary club head faceplate had less impurities and therefore less Al-Oxide than the control club head. The control club head that had an increase in Al-Oxide content was more susceptible to micro-cracks / fractures that resulted in earlier failure than the exemplary club head.CLAUSES

[0147] Clause 1. A golf club head comprises a body forming at least portions of a crown, a sole, a heel, and a toe; and a 3D printed faceplate coupled to the body to enclose an interior cavity. The 3D printed faceplate at least partially forms a strike face and includes a crown return forming at least a portion of the crown, a sole return forming at least a portion of the toe, a heel return forming at least a portion of the heel, and a leading edge between the strike face and the sole return. The 3D printed faceplate is formed by Selective Laser Melting a C300 metallic powder comprising between 0.02% and 0.15% Al. The C300 powder further comprises a sphericity greater than or equal to 95%. An Impact Response Modulator (IRM) is disposed in the sole and comprises a casing entirely integral with the sole return and spaced rearward from the strike face by a forward sole region. The casing includes a front wall extending upward from the sole into the interior cavity, the front wall comprising a front wall front surface, a front wall rear surface, a front wall base, a front wall top surface, and a front wall thickness. A rear wall is spaced rearward from the front wall and extends upward from the sole into the interior cavity, the rear wall comprising a rear wall front surface, a rear wall rear surface, a rear wall base, and a rear wall top surface. A toe wall extends between the front wall and the rear wall at a toe end of the casing, and a heel wall extends between the front wall and the rear wall at a heel end of the casing. The front wall, rear wall, toe wall, and heel wall border an aperture.

[0148] Clause 2. The golf club head of clause 1, wherein the faceplate further comprises a faceplate perimeter that is continuously attached to the body.

[0149] Clause 3. The golf club head of clause 1, wherein the crown return further comprises a crown return interior surface and a crown return indent recessed into the interior surface.

[0150] Clause 4. The golf club head of clause 1, wherein the crown return comprises a crown return thickness and the crown return indent comprises an indent thickness of 0.005 to 0.020 inch.

[0151] Clause 5. The golf club head of clause 4, wherein the crown return comprises an indent thickness ratio defined as the indent thickness divided by the crown thickness, and wherein the indent thickness ratio is less than 0.5.

[0152] Clause 6. The golf club head of clause 1, wherein the casing comprises a toe end reinforcement near the toe wall and having a toe end reinforcement thickness that is at least 50% greater than the front wall thickness.

[0153] Clause 7. The golf club head of clause 1, wherein the casing comprises an offset distance, measured between the leading edge and the front wall base in a front-to-rear direction, of 0.075 to 0.5 inch.

[0154] Clause 8. The golf club head of clause 1, wherein the body is formed of a body material having a body material yield strength and the faceplate is formed of a faceplate material having a faceplate material yield strength greater than the body material yield strength.

[0155] Clause 9. The golf club head of clause 8, wherein the faceplate material yield strength is greater than 175 ksi.

[0156] Clause 10. The golf club head of clause 8, further comprising a faceplate strength ratio, defined as the ratio of the faceplate material yield strength divided by the body material yield strength, greater than 1.25.

[0157] Clause 11. The golf club head of clause 1, wherein the C300 powder further comprises less than or equal to 0.03% C, less than or equal to 0.1% Si, less than or equal to 0.01% S, less than or equal to 0.01% P, and less than or equal to 0.1% Mn.

[0158] Clause 12. The golf club head of clause 11, wherein the C300 powder further comprises between 18-19% Ni, between 4.6-5.2% Mo, between 0.5% and 0.8% Ti, and between 8.5% and 9.5% Co.

[0159] Clause 13. The golf club head of clause 12, wherein the C300 powder comprises between 0.02-0.04% Al.

[0160] Clause 14. The golf club head of clause 12, wherein the C300 powder comprises between 0.05-0.15% Al.

[0161] Clause 15. The golf club head of clause 12, wherein the C300 powder comprises a fluidity that is less than or equal to 20s / 50 g.

[0162] Clause 16. The golf club head of clause 12, wherein the C300 powder further comprises a fluidity that is greater than or equal to 25s / 50 g.

[0163] Clause 17. The golf club head of clause 13, wherein the C300 powder further comprises a D10 grain size ranging from 16-23 μm, a D50 grain size ranging from 30-40 μm, and a D90 grain size ranging from 50-60 μm.

[0164] Clause 18. The golf club head of clause 1, further comprising an insert disposed within the aperture.

[0165] Clause 19. A golf club head comprises a body forming at least portions of a crown, a sole, a heel, and a toe; and a 3D printed faceplate coupled to the body to enclose an interior cavity. The 3D printed faceplate at least partially forms a strike face and includes a crown return forming at least a portion of the crown, a sole return forming at least a portion of the toe, a heel return forming at least a portion of the heel, and a leading edge between the strike face and the sole return. The 3D printed faceplate is formed by Selective Laser Melting a C300 metallic powder comprising between 0.02% and 0.15% Al. The C300 powder further comprises a sphericity greater than or equal to 95%. An Impact Response Modulator (IRM) is disposed in the sole and comprises a casing entirely integral with the sole return and spaced rearward from the strike face by a forward sole region. The casing includes a front wall extending upward from the sole into the interior cavity, the front wall comprising a front wall front surface, a front wall rear surface, a front wall base, a front wall top surface, and a front wall thickness, wherein the strike face, the forward sole region, and the front wall combine to collectively define a U-shaped trough disposed toward and in fluid communication with the interior cavity. A rear wall is spaced rearward from the front wall and extends upward from the sole into the interior cavity, the rear wall comprising a rear wall front surface, a rear wall rear surface, a rear wall base, and a rear wall top surface. A toe wall extends between the front wall and the rear wall at a toe end of the casing, and a heel wall extends between the front wall and the rear wall at a heel end of the casing. The front wall, rear wall, toe wall, and heel wall border an aperture.

[0166] Clause 20. The golf club head of clause 1, wherein the front wall further comprises a geometry selected from the group consisting of: a front wall step at or near the front wall top surface, a front wall undercut recessed into the front wall front surface, a front wall cavity encapsulated within the front wall, and a front wall crossbeam forming the front wall top surface.

Claims

1. A golf club head, comprising:a body forming at least portions of a crown, a sole, a heel, and a toe;a 3D printed faceplate coupled to the body to enclose an interior cavity, the 3D printed faceplate at least partially forming a strike face and including a crown return forming at least a portion of a crown, a sole return forming at least a portion of a toe, a heel return forming at least a portion of a heel, and a leading edge between the strike face and the sole return;the 3D printed faceplate formed by Selective Laser Melting a C300 metallic powder comprising between 0.02% and 0.15% Al;the C300 powder further comprising a sphericity greater than or equal to 95%;an Impact Response Modulator (IRM) disposed in the sole, the IRM comprising;a casing entirely integral with the sole return and spaced rearward from the strike face by a forward sole region, the casing including:a front wall extending upward from the sole into the interior cavity, the front wall comprising a front wall front surface, a front wall rear surface, a front wall base, a front wall top surface, and a front wall thickness;a rear wall spaced rearward from the front wall and extending upward from the sole into the interior cavity, the rear wall comprising a rear wall front surface, a rear wall rear surface, a rear wall base, and a rear wall top surface;a toe wall extending between the front wall and the rear wall at a toe end of the casing;a heel wall extending between the front wall and the rear wall at a heel end of the casing; andwherein the front wall, the rear wall, the toe wall, and the heel wall border an aperture.

2. The golf club head of claim 1, wherein the faceplate further comprises a faceplate perimeter that is continuously attached to the body.

3. The golf club head of claim 1, wherein the crown return further comprises a crown return interior surface and a crown return indent recessed into the interior surface.

4. The golf club head of claim 1, wherein the crown return comprises a crown return thickness and the crown return indent comprises an indent thickness of 0.005 to 0.020 inch.

5. The golf club head of claim 4, wherein the crown return comprises an indent thickness ratio defined as the indent thickness divided by the crown thickness, and wherein the indent thickness ratio is less than 0.5.

6. The golf club head of claim 1, wherein the casing comprises a toe end reinforcement near the toe wall and having a toe end reinforcement thickness that is at least 50% greater than the front wall thickness.

7. The golf club head of claim 1, wherein the casing comprises an offset distance, measured between the leading edge and the front wall base in a front-to-rear direction, of 0.075 to 0.5 inch.

8. The golf club head of claim 1, wherein the body is formed of a body material having a body material yield strength and the faceplate is formed of a faceplate material having a faceplate material yield strength greater than the body material yield strength.

9. The golf club head of claim 8, wherein the faceplate material yield strength greater than 175 ksi.

10. The golf club head of claim 8, further comprising a faceplate strength ratio, defined as the ratio of the faceplate material yield strength divided by the body material yield strength, greater than 1.25.

11. The golf club head of claim 1, wherein the C300 powder further comprises less than or equal to 0.03% C, less than or equal to 0.1% Si, less than or equal to 0.01% S, less than or equal to 0.01% P, less than or equal to 0.1% Mn,12. The golf club head of claim 11, wherein the C300 powder further comprises between 18-19% Ni, between 4.6-5.2% Mo, between 0.5% and 0.8% Ti, and between 8.5% and 9.5% Co.

13. The golf club head of claim 12, wherein the C300 powder comprises between 0.02-0.04% Al.

14. The golf club head of claim 12, wherein the C300 powder comprises between 0.05-0.15% Al.

15. The golf club head of claim 12, wherein the C300 powder comprises a fluidity that is less than or equal to 20s / 50 g.

16. The golf club head of claim 12, wherein the C300 powder further comprises a fluidity that is greater than or equal to 25s / 50 g.

17. The golf club head of claim 13, wherein the C300 powder further comprises a D10 grain size ranging from 16-23 μm, a D50 grain size ranging from 30-40 μm, a D90 grain size ranging from 50-60 μm.

18. The golf club head of claim 1, further comprising an insert disposed within the aperture.

19. A golf club head, comprising:a body forming at least portions of a crown, a sole, a heel, and a toe;a 3D printed faceplate coupled to the body to enclose an interior cavity, the 3D printed faceplate at least partially forming a strike face and including a crown return forming at least a portion of a crown, a sole return forming at least a portion of a toe, a heel return forming at least a portion of a heel, and a leading edge between the strike face and the sole return;the 3D printed faceplate formed by Selective Laser Melting a C300 metallic powder comprising between 0.02% and 0.15% Al;the C300 powder further comprising a sphericity greater than or equal to 95%;an Impact Response Modulator (IRM) disposed in the sole, the IRM comprising;a casing entirely integral with the sole return and spaced rearward from the strike face by a forward sole region, the casing including:a front wall extending upward from the sole into the interior cavity, the front wall comprising a front wall front surface, a front wall rear surface, a front wall base, a front wall top surface, and a front wall thickness;wherein the strike face, the forward sole region, and the front wall combine to collectively define a U-shaped trough disposed toward and in fluid communication with the interior cavity;a rear wall spaced rearward from the front wall and extending upward from the sole into the interior cavity, the rear wall comprising a rear wall front surface, a rear wall rear surface, a rear wall base, and a rear wall top surface;a toe wall extending between the front wall and the rear wall at a toe end of the casing;a heel wall extending between the front wall and the rear wall at a heel end of the casing; andwherein the front wall, the rear wall, the toe wall, and the heel wall border an aperture.

20. The golf club head of claim 1, wherein the front wall further comprises a geometry selected from the group consisting of: a front wall step at or near the front wall top surface, a front wall undercut recessed into the front wall front surface, a front wall cavity encapsulated within the front wall, and a front wall crossbeam forming the front wall top surface.

Images