Abstract: A method for manufacture of a hollow complex three-dimensional fiber golf club head having at least one hole. A fluid-removable core is shaped in the general form of the golf club head, placed in a flexible pressurizable bladder around the core, at least one ply of fiber impregnated with a curable resin is wrapped over the core and bladder, and a cured part is formed by pressurizing the bladder while the core, bladder, and impregnated fiber is in a female mold to force the plies against the inner surfaces of the mold. After heating to cure the resin, the bladder and the fluid-removable core is removed from the interior of the cured part by disintegrating core with a fluid sufficient to allow removal of the bladder.

Abstract: Disclosed is a method for manufacture of a hollow complex three-dimensional fiber golf club head having at least one hole. The method involves shaping a fluid-removable core in the general form of the golf club head, placing a flexible pressurizable bladder around the core, wrapping over the assembly of core and bladder at least one ply of fiber impregnated with a curable resin, forming a cured part by pressurizing the bladder while the assembly of core, bladder, and impregnated fiber is in a female mold to force the plies against the inner surfaces of the mold, such that compaction of the fiber against the inner surfaces of the mold is from the pressurization of the bladder and not from the core, and heating to cure the resin, removing the bladder and the fluid-removable core from the interior of the cured part by first disintegrating and removing the fluid-removable core with a fluid sufficient to allow removal of the bladder.

Abstract: Bicycle frame components without laps made by a method comprising; shaping a fluid-removable core in the general form of the component, placing a flexible inflatable bladder around the core, wrapping over the assembly of core and bladder at least one ply of fiber impregnated with a curable resin, forming a cured part by inflating the bladder while the assembly of core, bladder, and impregnated fiber is in a mold to force the plies against the inner surfaces of the mold, such that compaction of the fiber against the mold is predominantly from the bladder inflation and not from the core, and heating to cure the resin to form a cured part, removing the bladder and the fluid-removable core from the interior of the cured part by disintegrating the fluid-removable core with a fluid sufficient to allow removal of the core and the bladder.

Abstract: Bicycle frame components without laps made by a method comprising; shaping a fluid-removable core in the general form of the component, placing a flexible inflatable bladder around the core, wrapping over the assembly of core and bladder at least one ply of fiber impregnated with a curable resin, forming a cured part by inflating the bladder while the assembly of core, bladder, and impregnated fiber is in a mold to force the plies against the inner surfaces of the mold, such that compaction of the fiber against the mold is predominantly from the bladder inflation and not from the core, and heating to cure the resin to form a cured part, removing the bladder and the fluid-removable core from the interior of the cured part by disintegrating the fluid-removable core with a fluid sufficient to allow removal of the core and the bladder.

Abstract: A composite golf-club head is disclosed with at least one complex three-dimensional molded composite part. The part has multiple interleaved plies of reinforcing fiber, and has a wall with an interleave ratio greater than about 30, preferably greater than about 100.

Abstract: A process for manufacturing a golf-club head is disclosed comprising; shaping a fluid-removable core in the general form of the club head, placing a flexible inflatable bladder around the core, wrapping over the assembly of core and bladder at least one ply of fiber impregnated with a curable resin, placing the assembly of core, bladder, and impregnated fiber into a female mold, forming a cured part in the form of a golf-club head by inflating the bladder to force the plies against the inner surfaces of the mold and heating the mold to cure the resin, removing the cured part from the mold, disintegrating the fluid-removable core with a fluid sufficient to allow removal of the bladder from the interior of the cured part through a hole in the cured part, removing the bladder through the hole with any residues of the core within the bladder to form a hollow molded club head with a hollow interior essentially free from non-functional materials.