Abstract: Methods of creating golf club components with complex structures that would be difficult, impossible, or cost prohibitive to produce, such as lattice structures, beam structures, and complex surface-based structures, are described herein. In particular, a binder jet machine is used create complex structures to optimize weighting, sound, and performance of golf club heads. The method preferably includes the steps of designing a golf club head component in CAD using optimization software, printing the component from a powdered material, and then removing excess powder from the component via port holes that extend into an external surface of the component and communicate with interior voids within the component.

Abstract: Lightweight, low-torque, composite golf club shafts with bent tips and methods of manufacturing such golf club shafts are disclosed herein. Some methods involve the use of pre-bent, rigid tubes that remain inside the finished composite shafts to support their bent tip structures. Other methods require the use of cores (which may be flexible and/or dissolvable), which support the composite shaft precursors when they are placed into forming molds to form the bent tips. These cores may be removed at the end of the bending process. Still other methods incorporate the use of bladders to provide support for shaft tips when they are subjected to molding forces.

Abstract: A pickleball paddle is disclosed herein. The pickleball paddle includes a body with a face section and a handle section. The face section has a perimeter. A grip is attached to the handle section. Weighting is positioned in the perimeter of the face section.

Abstract: Methods of applying a polymeric coating to a rear face surface of golf club heads with variable face thickness are disclosed herein. The coating, which preferably comprises polyurea, improves the durability of the face and reduces the hits to failure ratio of the golf club head. The coating improves the performance of the golf club head because it allows for reduction in overall face thickness and easy post-process manipulation to allow for fine-tuning of mass properties after production. The reduction in thickness leads to overall weight reduction, because the polymer is roughly a quarter of the density of titanium or stainless steel, and also reinforces the face, thereby increasing the lifespan of the club.