Abstract: A method of making golf clubs of thermoplastic composite material is disclosed. The present method is characterized in that the composite material wound around a mandrel is consolidated by using a metal sheet. This method comprises the steps of: (a) providing a tapered mandrel, and wrapping the mandrel with at least a sheet of thermoplastic prepreg to form a laminated outer shell; (b) heating the thermoplastic prepreg to a molten state; (c) enclosing the laminated outer shell with at least a metal sheet, and heating the metal sheet and the laminated outer shell while constricting said metal sheet to thereby consolidate the molten prepreg to form a tubular body; and (d) releasing the metal sheet and withdrawing the mandrel from the tubular body.

Abstract: A method of molding a composite bicycle frame that includes the steps of curing a pair of seat stays and chain stays respectively and then connecting with the front triangle. Non-foaming dilatable materials are provided at suitable locations in the mold, such as the steering support cavity, the pedal support cavity, the seat stay butting cavity and the chain stay butting cavity. By heating the mold once, the seat stays and chain stays will secure with the front triangle and the front triangle can be cured at the same time to simplify the mold and the process.

Abstract: A method for manufacturing a composite bicycle frame adapts stepped forming. The seat stays combined with the seat support means which are connected to parts of the top tube and seat tube, and the chain stays combined with the pedal support means which are connected to parts of the down tube and seat tube, are formed respectively. The seat stays connect to the chain stays by inserting a pair of rear wheel dropouts therebetween, to form substantially a pair of rear triangles of the bicycle frame. The seat tube and the steering support means connected to the top tube and down tube are laid up respectively. The cured rear triangles connect to uncured seat tube and steering support means associated with top tube and down tube, wherein the top tube, down tube, and seat tube form a front triangle. The front triangle is cured such that manufacturing of the whole bicycle frame is completed.