3D-Printed Hybrid Golf Ball Core for Layered Performance Tuning
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Solution Overview
Problem
Existing golf ball constructions lack diversity in layer configurations beyond traditional spherical designs, limiting opportunities for improved performance and feel.
Innovation Solution
A golf ball core is constructed with a first layer formed via three-dimensional printing, featuring a hub and spokes extending in various directions, and a second layer formed via molding, utilizing distinct materials for enhanced properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional spherical molding processes are used for golf ball core construction, then manufacturing simplicity is maintained, but layer configuration diversity and performance optimization opportunities are limited
Solution Approach 1:
The core is divided into multiple layers with different functions: an inner core layer formed by 3D printing with hub and spoke structures, and an outer core layer formed by molding. This segmentation allows each layer to be optimized independently for specific performance characteristics while maintaining manufacturing feasibility through separate process steps.
Solution Approach 2:
The invention transitions from traditional two-dimensional spherical layer construction to three-dimensional complex geometries with hub and spoke structures. The 3D printing process enables radial and circumferential spoke extensions, curved profiles, and asymmetrical configurations that cannot be achieved with conventional spherical molding, adding structural dimensionality and design freedom.
2Adaptability or versatility
If hybrid manufacturing processes (3D printing + molding) are used for core construction, then unique layer configurations and material properties are achieved, but manufacturing complexity increases
Solution Approach 1:
The inner core layer with hub and spoke structures is pre-formed using 3D printing before the outer core layer is molded around it. This preliminary action allows the complex three-dimensional structure to be created first, then encapsulated in a single molding operation, rather than requiring complex multi-step molding processes.
Solution Approach 2:
The hub and spoke structures serve as intermediary elements between the inner and outer core layers. These structures provide a transition zone that allows the two differently manufactured layers to integrate, with the spokes extending into the outer layer and creating mechanical interlocking and stress distribution pathways.
3Strength
If spokes extend in multiple directions (radial and circumferential) with complex profiles, then structural performance and energy management are optimized, but manufacturing precision requirements increase
Solution Approach 1:
The 3D printing process is self-service for creating complex spoke geometries, as it can directly fabricate curved, asymmetrical, and irregular profiles without requiring additional tooling or post-processing. The additive nature of 3D printing inherently handles complex three-dimensional geometries that would be difficult or impossible to achieve with subtractive or formative manufacturing methods.
Data Source
AI summary
A golf ball is disclosed herein that includes a core comprised of two distinct layers. A first core layer is formed from three-dimensional printing and has a non-spherical profile. A second core layer is formed from traditional core layer formation techniques around the first core layer. The first core layer can have a profile that is comprised of a central hub, which can be spherical or non-spherical, and a plurality of spokes extending therefrom. The spokes can have an elongated shape and can have a length greater than a diameter of the hub. The spokes can further include branches extending therefrom.