Additive-Manufactured Golf Club Heads With Segmented Mass Distribution
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Solution Overview
Problem
Conventional golf club head manufacturing processes are limited in customization and geometric complexity, restricting the ability to leverage performance advantages from various club head types in a single club head.
Innovation Solution
The use of 3D printing or additive manufacturing techniques to create golf club heads with segmented or lattice structures, allowing for customizable performance characteristics such as CG location, MOI, and material properties.
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 geometric complexity is significantly reduced
Solution Approach 1:
The club head is divided into multiple regions with different material densities (e.g., high-density weights and low-density voids or alternative materials) that can be independently positioned and configured. This segmentation allows precise control over CG location and MOI while maintaining manufacturing feasibility through additive manufacturing processes
Solution Approach 2:
The invention employs composite construction by combining materials with different densities and properties within the club head structure. This includes integrating high-density materials (such as tungsten or steel weights) with lower-density materials or void spaces to achieve customized mass distribution and performance characteristics that cannot be obtained through conventional monolithic manufacturing
2Shape
If conventional manufacturing processes are used, then production is efficient, but geometric complexity such as undercut or hollow constructions cannot be readily produced
Solution Approach 1:
The complex 3D geometry is designed and prepared in advance using computer-aided design (CAD) software, allowing the manufacturing process to directly produce the final complex shape without requiring post-forming operations. The mold or build platform is pre-configured with the exact geometry needed, eliminating the need for complex post-processing steps
3Strength
If a large-volume hollow construction club head is manufactured, then MOI is increased, but CG location flexibility is reduced due to volume-based constraints
Solution Approach 1:
Different regions of the club head are assigned different material densities and properties to achieve both high MOI and flexible CG location. High-density materials are strategically placed in specific zones to increase MOI, while low-density regions or void spaces are positioned to allow CG adjustment. This local differentiation of material properties enables simultaneous optimization of both parameters
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
Enables the production of golf club heads with tailored performance characteristics, including customizable CG locations and material densities, overcoming the limitations of conventional manufacturing methods.
Implementation Method 1
bonding, using an energy source, portions of the layer of powdered material
Implementation Method 2
bonding, using an energy source, portions of the layer of powdered material
Data Source
AI summary
A process of manufacturing a golf club component includes the step of spreading a layer of powdered material over a build plane defined over a build platform. Another step includes bonding, using an energy source, portions of the layer of powdered material. A different step includes repeating the spreading and bonding until the golf club component is formed. The process further includes the step of extracting loose powdered material from the golf club component. The build plane is offset from a ground plane between about 5 degrees and about 160 degrees. The ground plane is defined as a horizontal plane parallel to the ground when the golf club component is at address, and the build plane is not a face angle of the golf club component.