Abstract: A process for the custom design and automated, custom manufacture of golf clubs. According to a first embodiment, a computer user interface, preferably a graphical user interface (GUI), guides a user's selection of preferred golf club design parameters. According to a second embodiment, input data about a golfer's style of play and golf club performance needs are captured from data collection systems, and analyzed by black box algorithms, preferably fuzzy logic algorithms, to infer golf club design parameters. After preferences for, or inferences about, golf club design parameters are developed in accordance with the two embodiments, a computer aided (CA) system is used to design and manufacture the desired golf clubs.

Abstract: The present invention is directed to a golf club head with an improved striking surface. Grooves are machined into the strike surface with tight tolerances. The grooves have sharp edges, radiused ends, and a draft angle between about 2° and 12°. The striking face is machined such that it has a uniform texture with a roughness of more than 40 Ra. The grooves may contain a plurality of portions, including a radiused or angled portion, a portion having substantially parallel walls, a portion having a v-shape, and a curved portion. The grooves may also be characterized by various dimensions, including draft angle, inclusive side wall angle, width, depth, cross-sectional area, spacing, and pitch ratio. Preferred values for these dimensions are provided. A golf club head having a variety of groove types and a set of golf clubs with grooves varying among the individual clubs of the set are also disclosed.

Abstract: A set of iron-type golf clubs includes long irons with channel back configurations and short irons with cavity back configurations. The rear face configurations transition from channel backs through to pure cavity backs for increased performance continuum for the set. Additional design parameters for the set may also be systematically varied through the set, such as groove type and depth, loft angle, cavity volume, hitting face roughness, and sole width. At least one of the clubs of the set includes a sandwich-type construction for the hitting face having a dampening element disposed between a hitting face insert and a lightweight reinforcing core. In one embodiment, at least one club head is oversized.

Abstract: The present invention is directed to a golf club head with an improved striking surface. The grooves are machined into the strike surface with tight tolerances. The grooves have sharp edges, radiused ends, and a draft angle between about 2° and 12°. The striking face is machined such that it has a uniform texture with a roughness of more than 40 Ra. The grooves may contain a plurality of portions, including a radiused or angled portion, a portion having substantially parallel walls, a portion having a v-shape, and a curved portion. The grooves may also be characterized by various dimensions, including draft angle, inclusive side wall angle, width, depth, cross-sectional area, spacing, and pitch ratio. Preferred values for these dimension are provided.

Abstract: A set of iron-type golf clubs includes long irons with cavity back configurations and short irons with muscle back configurations. The rear face configurations slowly transition from pure cavity back through cavity-muscle backs to pure muscle backs for increased performance continuum for the set. Additional design parameters for the set may also be systematically varied through the set, such as face area, loft angle, offset and location of the center of gravity.

Abstract: A set of iron-type golf clubs includes long irons with channel back configurations and short irons with cavity back configurations. The rear face configurations transition from channel backs through to pure cavity backs for increased performance continuum for the set. Additional design parameters for the set may also be systematically varied through the set, such as groove type and depth, loft angle, cavity volume, hitting face roughness, and sole width. At least one of the clubs of the set includes a sandwich-type construction for the hitting face having a dampening element disposed between a hitting face insert and a lightweight reinforcing core. In one embodiment, at least one club head is oversized.

Abstract: A set of iron clubs where each club in the set has the same or substantially the same ground roll. The set is produced by adjusting at least two club design characteristics of the clubs based upon measured or assumed player swing data. The design characteristics of the clubs include club length, static clubhead loft, location of the center of gravity, shaft flexibility, and groove volume. Preferably, club length and static clubhead loft are adjusted for coarse adjustments, while the other characteristics are used to fine-tune the design.

Abstract: An iron-type golf club includes a conventional-weight section, a lightweight section and a heavyweight section. The conventional-weight section includes the hitting face and at least a portion of the hosel. The heavyweight section, made of a denser material than the conventional-weight section, includes the sole and an optional back flange. The lightweight section, made of a material less dense than either of the other sections, includes a core to which the other two sections are secured, such as by co-molding the core to the other two sections. The heavyweight section includes anchoring structures to which the lightweight section can securely attach. This arrangement maintains the overall weight of the club head compared to a similarly proportioned conventional club head while shifting the center of gravity low and aft. As such, the club head provides benefits such as forgiveness for thin shots, heel/toe shots, and provides longer drives with less roll.

Abstract: Disclosed herein are muscle-back iron golf clubs that have improved mass qualities to provide higher rotational moments of inertia and lower center of gravity while retaining the workability of muscle-back irons and the size, shape and dimensions preferred by tour players and low handicap players.

Abstract: A golf club head and a method of making a golf club head includes a framework that is applied to the rear portion of the club head. A heat shrinkable membrane is mounted to the framework, by either mechanical means or by application of a bonding agent, creating a hollow golf club wherein the membrane material at the center of the rear portion is taut and exposed. The membrane is made from a conformable heat shrinkable fabric having a high tensile strength and negligible compressive strength. The fabric comprises thin, relative flexible, long interwoven fibers such as Kevlar, canvas, sailcloth and fabrics used in the skins of airplanes.

Abstract: A hollow golf club having a hosel sleeve weight made from tungsten material in the upper hosel area and a tungsten toe plug in the lower toe portion of the club head. This combination creates an increase in the moment of inertia of the club head about the x, y and z axes of the club head. A composite core is bladder molded into a cavity in the club head to provide support for a relatively thin front face and the composite core is visible on the rear surface of the club head. The core material is less dense and has greater flexibility than the front face.

Abstract: A set of iron-type golf clubs includes long irons with channel back configurations and short irons with cavity back configurations. The rear face configurations transition from channel backs through to pure cavity backs for increased performance continuum for the set. Additional design parameters for the set may also be systematically varied through the set, such as groove type and depth, loft angle, cavity volume, hitting face roughness, and sole width. At least one of the clubs of the set includes a sandwich-type construction for the hitting face having a dampening element disposed between a hitting face insert and a lightweight reinforcing core. In one embodiment, at least one club head is oversized.

Abstract: The present invention is directed to a golf club head with an improved striking surface. The grooves are machined into the strike surface with tight tolerances. The grooves have sharp edges, radiused ends, and a draft angle between about 2° and 12°. The striking face is machined such that it has a uniform texture with a roughness of more than 40 Ra.

Abstract: A set of iron-type golf clubs includes long irons with channel back configurations and short irons with cavity back configurations. The rear face configurations transition from channel backs through to pure cavity backs for increased performance continuum for the set. Additional design parameters for the set may also be systematically varied through the set, such as groove type and depth, loft angle, cavity volume, hitting face roughness, and sole width. At least one of the clubs of the set includes a sandwich-type construction for the hitting face having a dampening element disposed between a hitting face insert and a lightweight reinforcing core. In one embodiment, at least one club head is oversized.

Abstract: A set of iron-type golf clubs includes long irons with channel back configurations and short irons with cavity back configurations. The rear face configurations transition from channel backs through to pure cavity backs for increased performance continuum for the set. Additional design parameters for the set may also be systematically varied through the set, such as groove type and depth, loft angle, cavity volume, hitting face roughness, and sole width. At least one of the clubs of the set includes a sandwich-type construction for the hitting face having a dampening element disposed between a hitting face insert and a lightweight reinforcing core. In one embodiment, at least one club head is oversized.