Method and system of manufacturing a golf club, and a manufactured golf club head

Abstract

A method of manufacturing a custom golf club, the method including measuring swing dynamics of a user, determine club design parameters based on the measure swing dynamics of the user, generating a computer model representing an custom golf club head based on the determined design parameters, and manufacturing the custom golf club head based on the generated computer model using additive layer manufacturing processes using powder material and a high energy beam.

1 . A method of manufacturing a custom golf club, the method comprising:
 measuring, using a launch monitor, dynamic launch aspects of a golf swing, and flight characteristics imparted to a golf ball thereby, of a user when the user swings a regular golf club;   determining at least one club parameter selected from a plurality of club parameters based on the measured dynamic launch aspects and flight characteristics as a result of the user's golf swing;   generating a computer model representing a shape for single piece, at least partially hollow section for a custom golf club head based on the determined at least one club parameter; and   manufacturing the custom golf club head based on the generated computer model using additive layer manufacturing processes using powder material and a high energy beam to form a supporting lattice and an exterior surface around the supporting lattice concurrently.   
     
     
         2 . The method of  claim 1 , wherein the measured swing dynamics include at least one of golf club swing speed, golf ball launch spin rate and golf ball launch angle. 
     
     
         3 . The method of  claim 1 , wherein the determining golf club design parameters comprises determining at least one of:
 Hosel offset;   Club head volume;   Club face height;   Club face length;   Placement of visual alignment aids;   Club head Sole curvature;   Club head sole bounce; and   Club head sole grid.   
     
     
         4 . The method of  claim 1 , wherein the determining golf club design parameters comprises adjusting at least one of:
 Club head face thickness;   Club head face (hitting surface) center of gravity; and   Club head face thickness geometry.   
     
     
         5 . The method of  claim 1 , wherein the determining golf club design parameters comprises adjusting at least one of:
 Golf Club Head weight; and   Placement of center of gravity.   
     
     
         6 . The method of  claim 1 , wherein the generating a computer model comprises:
 Selecting a base model of a golf club head from a plurality of predefine club head models;   Modifying the base model based on the determined club design parameters determined based on the measured swing dynamics.   
     
     
         7 . The method of  claim 6 , wherein the base model comprises at a model of at least one of a driver model, fairway wood model; hybrid model; iron model; wedge model; and putter model. 
     
     
         8 . The method of  claim 6 , wherein the modifying the base model comprises changing at least one of:
 Hosel offset;   Club head volume;   Club face height;   Club face length;   Placement of visual alignment aids;   Club head Sole curvature;   Club head sole bounce; and   Club head sole grid of the base model.   
     
     
         9 . The method of  claim 1 , wherein the manufactured ideal golf club head comprises a metal unibody golf club head having no welds and at least a partially hollow section or area. 
     
     
         10 . The method of  claim 9 , wherein the manufactured ideal golf club head comprises hollow golf club head. 
     
     
         11 . The method of  claim 1 , wherein the manufactured ideal golf club head comprises a hollow golf club head having a supporting lattice formed within the hollow golf club head. 
     
     
         12 . The method of  claim 1 , wherein the manufactured golf club head comprises a hollow portion having at least one internal rib formed therein. 
     
     
         13 . The method of  claim 1 , wherein the manufactured golf club head comprises an engineered texture or design formed in at least one surface thereof. 
     
     
         14 . The method of  claim 1 , wherein the manufactured golf club head comprises at least one attachment feature. 
     
     
         15 . The method of  claim 14 , wherein the at least one attachment feature is selected from at least one of:
 a clip;   a snap;   a pocket;   a threaded surface; and   a slot.   
     
     
         16 . A method of manufacturing a custom golf club, the method comprising:
 measuring, using a launch monitor, dynamic launch aspects of a golf swing, and flight characteristics imparted to a golf ball thereby, of a user when the user swings a regular golf club;   determining at least one club parameter selected from a plurality of club parameters based on the measured dynamic launch aspects and flight characteristics as a result of the user's golf swing;   generating a computer model representing a shape for single piece, at least partially hollow section for a portion of a custom golf club head based on the determined design parameters;   manufacturing the portion of the custom golf club head based on the generated computer model using additive layer manufacturing processes using powder material and a high energy beam to form a supporting lattice and an exterior surface around the supporting lattice concurrently;   Attaching the portion of the custom golf club head to a preformed partial club head to assemble the custom golf club head.   
     
     
         17 . The method of  claim 16 , wherein the manufactured portion of the custom golf club head is at least one of:
 A crown plate;   A sole plate;   A hitting face plate;   A cup face (wrapped face section); and   A hosel.   
     
     
         18 . The method of  claim 16 , wherein the preformed partial club head is formed using at least one of:
 a stamping process;   a casting process; and   a forging process.   
     
     
         19 . The method of  claim 16 , wherein the manufactured portion is attached to the preformed partial club head by at least one of:
 a welding process;   a bonding process;   a brazing process; and   a screw attachment process.   
     
     
         20 . A method of manufacturing a golf club head with less material waste, the method comprising:
 generating a computer model of a golf club head;   providing a quantity a powdered material;   applying a controlled source of energy to a used portion of the quantity metal layer by layer to form the golf club head; and   recapturing an unused portion of powdered material and saving the unused portion of the quantity of metal powder to be used for other manufacturing.   
     
     
         21 . The method of  claim 20 , wherein the golf club head is a hollow golf club head and wherein recapturing an unused portion of powdered material comprises forming a hole through a wall of the hollow golf club head; and drawing unused powder material from the hollow interior of the golf club head through the hole.