Laser Cutting Golf Ball Dimples Without Molds
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Solution Overview
Problem
The existing methods for manufacturing golf balls with different dimple patterns are time-consuming and require molds, limiting flexibility in creating and adjusting dimple shapes and sizes.
Innovation Solution
A system and method using laser cutting to create dimples and textures on golf ball cover layers, allowing for quick prototyping and adjustment of dimple patterns without the need for molds, utilizing a laser cutting machine with a computer numerical controller to precision-cut the outer layer of the golf ball.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional mold-based methods are used to create dimples on golf balls, then the manufacturing process is well-established and reliable, but the process is time-consuming and inflexible when creating different dimple patterns
Solution Approach 1:
The patent replaces the mechanical mold-based dimple creation system with a laser-based system. The laser cutting head can precisely remove material to create various dimple patterns without requiring physical molds, enabling rapid prototyping and pattern changes through software control rather than mechanical retooling
Solution Approach 2:
The patent changes the operational parameters of the laser system (power, speed, pulse duration) to optimize material removal rates and dimple quality. By adjusting these parameters, the system can efficiently create different dimple patterns while maintaining high precision and reducing production time compared to traditional molding methods
2Productivity
If molds are used to form dimples on golf balls, then consistent dimple patterns can be produced, but creating prototypes with different dimple patterns requires making new molds which is time-consuming
Solution Approach 1:
The patent eliminates the need for complex physical molds by using a laser cutting system that can be programmed through software. This substitution dramatically increases prototyping speed as pattern changes require only software modifications rather than manufacturing new molds, while maintaining consistent dimple quality through precise laser control
Solution Approach 2:
The patent uses digital models and software to represent different dimple patterns, allowing rapid copying and modification of designs. The laser system accurately reproduces these digital patterns on the golf ball surface, enabling quick iteration through virtual design changes rather than physical mold fabrication
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 rapid creation and adjustment of various dimple patterns and textures, reducing production time and eliminating mold-related limitations, facilitating golf ball testing and customization.
Implementation Method 1
laser cutting material from the outer layer of the base article in a predetermined pattern
Data Source
AI summary
A system and method for making golf balls is disclosed. The system may include laser cutting dimples into a golf ball cover layer. Laser cutting may also be used to add texture to the surface of a golf ball. Laser cutting dimples may provide flexibility in quickly creating different shapes, sizes, and patterns of dimples. Thus, during golf ball testing, a certain pattern of dimples may be made, tested, and then quickly adjusted. For example, the dimples may be adjusted by cutting away more cover material to make the dimples larger, deeper, and/or in a different shape. After further testing, the golf ball dimples may be adjusted again multiple times.