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: A resilient, high-performance face insert for a golf club head, preferably a putter head, is disclosed herein. In particular, the face insert comprises multiple layers of material, one or more of which may be manufactured using additive printing processes, and one or more of which may comprise variable thickness patterns to optimize ball speed, spin, and other performance characteristics.

Abstract: A golf club head, preferably a putter head, comprising at least one structural support member is disclosed herein. The structural support member has a smooth, organic-looking aesthetic, with a continuously changing curvature along its spline and at least one surface, and preferably connects one portion of the golf club head to another portion. Where the support member connects to other portions of the golf club head, the surfaces of the member have a curvature that changes smoothly and continuously, lacking any sharp corners. The support member may be part of a lattice structure formed via binder jetting.

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: Golf club components with complex such as lattice structures, beam structures, and complex surface-based structures, are described herein. A binder jet machine is used create complex structures within these golf club components to optimize weighting, sound, and performance of golf club heads. These components may be manufactured using a method that 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.