Additive Golf Club Head Structure for CG and MOI Customization
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Solution Overview
Problem
Conventional golf club head manufacturing processes are limited in customization and geometric flexibility, unable to leverage performance advantages from various club head types due to mold restrictions and geometric limitations, preventing the creation of complex geometries and tailored performance characteristics.
Innovation Solution
Golf club heads are manufactured using additive manufacturing techniques, allowing for the integration of segmented or lattice portions that enable customizable CG locations, MOI, mass properties, and performance characteristics through processes like metal powder bed fusion, DMLS, and binder jetting, enabling complex geometries and tailored designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional forging or casting processes are used to manufacture golf club heads, then the manufacturing process is simple and cost-effective, but the ability to customize CG location and tailor performance characteristics is significantly reduced due to mold restrictions
Solution Approach 1:
The patent applies additive manufacturing to fundamentally change the manufacturing parameters from subtractive/conventional processes to layer-by-layer deposition. This enables continuous adjustment of CG location and performance characteristics by modifying digital models during the manufacturing process, achieving high customization without traditional mold constraints
Solution Approach 2:
The patent replaces the mechanical mold-based forming system with a digital additive manufacturing system. Instead of being constrained by physical mold geometries, the club head is built layer-by-layer according to digital designs, eliminating the mechanical limitations of traditional forming processes and enabling complex internal structures and optimized CG locations
2Shape
If conventional manufacturing processes are used, then the production method is well-established and reliable, but complex geometries such as undercut or hollow constructions cannot be readily produced
Solution Approach 1:
The additive manufacturing process changes the geometric parameters from conventional manufacturing by enabling free-form geometries, undercuts, and hollow structures that are built layer-by-layer. This allows complex shapes to be manufactured directly without requiring complex mold assemblies or multiple manufacturing steps
Solution Approach 2:
The manufacturing process segments the club head into thin layers that are deposited sequentially. This segmentation enables the creation of complex internal geometries, hollow constructions, and integrated features that would be impossible to achieve with conventional monolithic manufacturing methods
3Adaptability or versatility
If conventional club head manufacturing processes are used, then the process is optimized for specific club head types, but the ability to leverage advantages from various club head types in a single club head is limited
Solution Approach 1:
The additive manufacturing process creates a universal manufacturing approach that can produce any club head type or hybrid design in a single process. The digital model can integrate features from different club head types (e.g., hollow construction for MOI, strategic material placement for CG control) without requiring separate manufacturing processes for each feature
Solution Approach 2:
The patent applies local quality by selectively depositing material only where needed to achieve specific performance characteristics. Different regions of the club head can have different material densities, hollow vs. solid constructions, and CG distributions optimized for specific functions, all within a single additive manufacturing process
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The additive manufacturing process allows for customizable golf club heads with optimized performance characteristics, such as CG location, MOI, and material density, overcoming the limitations of conventional methods by providing a single club head that combines advantages from different types.
Implementation Method 1
The front face and the body are formed of a sintered material by the additive manufacturing process
Data Source
AI summary
A golf club head includes a body formed by an additive manufacturing process. The body defines a toe region, a heel region, and a medial region positioned between the toe region and the heel region. A front face extends across the toe region, medial region, and the heel region and is formed of a sintered material. The body further includes a topline along a top side and a sole along a bottom side, each extending in a heel-toe direction. A plurality of grooves are disposed on the front face. The golf club head defines an internal cavity at least partially enclosed by the front face and the body. The internal cavity extends between the topline and the sole. A plurality of voids are defined by a rear surface of the front face.