U.S. patent application number 15/456307 was filed with the patent office on 2017-06-29 for method and system of manufacturing a golf club, and a manufactured golf club head.
The applicant listed for this patent is KRONE GOLF LIMITED. Invention is credited to Drew T. Deshiell, Marc Andrew Kronenberg.
Application Number | 20170185070 15/456307 |
Document ID | / |
Family ID | 51531415 |
Filed Date | 2017-06-29 |
United States Patent
Application |
20170185070 |
Kind Code |
A1 |
Kronenberg; Marc Andrew ; et
al. |
June 29, 2017 |
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.
Inventors: |
Kronenberg; Marc Andrew;
(Hobe Sound, FL) ; Deshiell; Drew T.; (Oceanside,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
KRONE GOLF LIMITED |
Hobe Sound |
FL |
US |
|
|
Family ID: |
51531415 |
Appl. No.: |
15/456307 |
Filed: |
March 10, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13836999 |
Mar 15, 2013 |
9594368 |
|
|
15456307 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B23K 26/342 20151001;
G05B 2219/49018 20130101; B33Y 80/00 20141201; A63B 53/04 20130101;
G05B 19/4099 20130101; G05B 2219/35134 20130101; B33Y 50/02
20141201; B33Y 10/00 20141201; G05B 19/4097 20130101; B23K 15/0086
20130101; A63B 53/0408 20200801 |
International
Class: |
G05B 19/4097 20060101
G05B019/4097; B33Y 50/02 20060101 B33Y050/02; A63B 53/04 20060101
A63B053/04; B23K 15/00 20060101 B23K015/00; B23K 26/342 20060101
B23K026/342; B33Y 10/00 20060101 B33Y010/00; B33Y 80/00 20060101
B33Y080/00 |
Claims
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.
Description
RELATED APPLICATION INFORMATION
[0001] The present application claims priority as a continuation to
U.S. patent application Ser. No. 13/836,999, is incorporated herein
by reference in its entirety as if set forth in full.
BACKGROUND
[0002] Field of the Invention
[0003] The field of invention relates generally to the fitting of
golf equipment and the manufacturing of golf equipment and more
particularly to systems and methods designed to improve a golfer's
swing and manufacture golf equipment customized to individual
golfer's swing.
[0004] Related Art
[0005] A wide variety of methods have been used to form clubs have
been used. Specifically, golf club heads have been forged or cast
and then ground or machined, and then polished to achieve desired
dimensions and appearances. However, these processes have a number
of short comings.
[0006] Further, golf club heads have generally been manufactured
with average dimensions based on an average user without any regard
to the specific needs and swing dynamics of specific golfers. This
was due to the expense and/or time required made customizing a head
mold to incorporate design changes extremely impractical. Thus, to
reduce cost and/or save time, a common mold has been used for the
head design regardless of the swing dynamics of users. However, not
all golfers are identical and many golfers may benefit from
optimization of club design parameters such as lie angle, loft
angle, or other design parameters. Through post-manufacturing
processing, such as grinding or bending with a vice, may allow some
custom fitting of clubs, these processes may have limited
effectiveness and can create additional problems such as metal
fatigue or weakening of the club.
[0007] Additionally, existing manufacturing techniques may also
require additional post processing, such as grinding, due to
manufacturing tolerances. Further, existing techniques have
limitations in the shapes and dimensions that can be produced.
[0008] Therefore, there is a need for golf club heads that can be
more customized based on a specific user's swing dynamics, as well
as manufacturing methods that can produce a wider variety of shapes
with tighter manufacturing tolerances.
SUMMARY
[0009] A general purpose of present application is a method of
manufacturing a golf club head that can customize more club design
parameters to a specific user's swing dynamics. Various embodiments
of the present application may provide a method of manufacturing a
golf club head by measuring a user's swing dynamics, determining
club design parameters based on measured swing dynamics, generating
a computer model of a club head based on the determined design
parameters, and using the computer model to manufacture the golf
club head using additive layer manufacturing processes using powder
material and a high energy beam.
[0010] An additional embodiment of the present application may also
provide a described herein may also include a system for
manufacturing a golf club, the system including a launch monitor
that measures a user's swing dynamics of a user, an club design
parameter determining engine that determines club design parameters
based on the measured swing dynamics of the user, a computer
modeler that generates a computer model representing a custom golf
club head based on the determined design parameters; and an
additive layer manufacturing device that manufactures the custom
golf club head based on the generated computer model using additive
layer manufacturing processes using powder material and a high
energy beam.
[0011] An additional embodiment of the present application may also
provide a method of manufacturing a custom golf club by measuring
swing dynamics of a user, determine club design parameters based on
the measure swing dynamics of the user, generating a computer model
representing 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, and attaching the portion of the custom golf club
head to a preformed partial club head to assemble the custom golf
club head.
[0012] Other features and advantages of the present application may
become more readily apparent to those of ordinary skill in the art
after reviewing the following detailed description and accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The structure and operation of the present invention will be
understood from a review of the following detailed description and
the accompanying drawings in which like reference numerals refer to
like parts and in which:
[0014] FIG. 1 is illustrates a flow chart showing a manufacturing
process of a custom golf club according to an embodiment of the
present application.
[0015] FIG. 2A is a diagram illustrating an additive layer
manufacturing apparatus using an electron beam, which may be used
in a method according to an embodiment of the present
application.
[0016] FIG. 2B is a diagram illustrating an additive layer
manufacturing apparatus using a laser beam, which may be used in a
method according to an embodiment of the present application.
[0017] FIG. 3 is a sectional diagram illustrating a plurality of
portions of a club that can be manufactured using a method
according to an embodiment of the present application.
[0018] FIG. 4 is a perspective view illustrating a core of a
sandwich or lattice structure that can be manufactured using a
method according to an embodiment of the present application.
[0019] FIG. 5 is a perspective view illustrating thin-film metal
structure that can be manufactured according to an embodiment of
the present application and applied to a club shaft.
[0020] FIG. 6 is a back or internal view illustrating a plurality
of club faces manufactured using a method according to an
embodiment of the present application.
[0021] FIG. 7 is a sectional view illustrating the plurality of
club faces shown in FIG. 6 manufactured using a method according to
an embodiment of the present applications.
[0022] FIG. 8 illustrates a hollow structure that can be
manufactured using a method according to an embodiment of the
present application.
[0023] FIG. 9 illustrates a plurality of additional types of
supporting lattice structures that can be manufactured using a
method according to an embodiment of the present application.
[0024] FIG. 10 is a diagram illustrating an example computing
environment with an example computing device that could be used to
perform a method according to an example implementation of the
present application.
DETAILED DESCRIPTION
[0025] Certain embodiments disclosed herein provide for a method of
manufacturing a golf club head. However, although various
embodiments of the present invention will be described herein, it
is understood that these embodiments are presented by way of
example only, and not limitation. As such, this detailed
description of various alternative embodiments should not be
construed to limit the scope or breadth of the present invention as
set forth in the appended claims.
[0026] FIG. 1 provides a flow chart showing a manufacturing process
100 for a custom golf club according to an embodiment of the
present application. In action 105, the user is interviewed to
provide initial background information to be used to design the
custom golf club. Specifically, a user may be asked to fill out a
questionnaire regarding the User's playing statistics. The User's
statistics may include, but are not limited to height, weight,
years of playing golf, handicap, putts per round, and #rounds per
year. Additionally, the user may also be asked about the current
golf tendencies including: trajectory of shots, swing path (i.e.
hook, slice, etc.) and consistency of shots. Further, the user's
goals regarding distance, ball trajectory, drawing, fading the
ball, etc.
[0027] After the user interview in action 105, the user's current
clubs may be measured in action 110 to obtain current club design
parameters that may be effecting the User's golf shots. In
particular, a variety of current club design parameters may be
measured including loft, lie, face angle, hosel offset, club
length, club weight, club swing weight, shaft weight, shaft flex,
grip size, grip weight, and any other parameters as would be
apparent to a person of ordinary skill in the art.
[0028] After the design parameters of the user's current clubs are
measured in action 105, the user's swing dynamics are analyzed in
action 115. Specifically, a user's swing dynamics or Launch
parameters with several clubs may be measured with a launch monitor
(such as trackman, foresight, etc.). Using the launch monitor, a
variety of swing dynamics or launch parameters are measured
including: head speed, launch angle, backspin, attack angle, ball
speed, swing plane angles, club path, spin axis, horizontal launch
angle, tempo, and any other parameters as would be apparent to a
person of ordinary skill in the art.
[0029] After swing dynamics or launch parameters are measured in
action 115, design parameters for the custom clubs are determined
in action 120 through a fitting process. Specifically, initial
fitting clubs determined based on the user's height, swing path,
and launch conditions. Then final head and club specifications are
determined by fitting for: [0030] Consistency by adjusting or
optimizing club length and lie by dynamic fitting; [0031] Distance
by adjusting club loft to optimize spin and clubhead speed by
dynamic fitting; [0032] Control by adjusting face angle to optimize
side spin by dynamic fitting; and [0033] Playability by adjusting
shaft, grip, total weight and swing weight for best feel.
[0034] From this fitting, club design parameters for the head and
final club components are determined. Head design specifications
are then determined from the fitting process to specify the optimal
head design and properties. Thus, the club specifications are
determined at least in part from the results of the dynamic fitting
process.
[0035] After the design parameters are determined in action 120, a
computer model of the club head is generated in action 125. Thus,
rather than modifying (i.e. by bending, adjusting weight) of
existing parts, a club head computer model is designed based on the
determined design parameters. In some embodiments, the club head id
generated by first by selecting a base model (Driver, Fairway Wood,
Hybrid, Iron, Wedge, Putter, etc.) from a library of club head
models. Then, club design parameters such as volume, loft, lie,
face angle, weight, CG properties, inertial properties, shape,
offset are entered into the base model which is then updated based
on the user's required specifications. Additionally, in some
embodiments, the face thickness and face thickness geometry (i.e.
back face geometry discussed in greater detail below) may be
adjusted based on the user's head speed and control tendencies. The
customized model can be encoded as a CAD file that will be used to
manufacture parts.
[0036] After the computer model is generated in action 125, the
club head can be manufactured using additive layer manufacturing
techniques that use powdered metal and high energy beams (such as a
laser or electron beam) in action 130.
[0037] Electron Beam Apparatus
[0038] FIG. 2A is a diagram illustrating an additive layer
manufacturing apparatus using an electron beam, which may be used
in a method according to an embodiment of the present application.
The manufacturing apparatus 200 includes an electron beam column
205 that generates an electron beam 240 by applying a voltage to a
filament 210. The generated electron beam 240 passes through a
plurality of lenses 215, 220, and 225 before entering the vacuum
chamber 235 where the club head is manufactured. The vacuum chamber
235 includes at least one powder hopper 245 filled with powdered
material 255 that will be melted to form the club head.
[0039] The powdered materials used can be a wide variety of
materials and including most metals including titanium (Ti), Steel,
Aluminum (Al), Titanium aluminum alloys (Titanium Aluminide or
TiAl), which generally cannot be cast or welded. More specifically,
example materials include, but are not limited to: [0040] Aluminum
Alloys .about.2.86 g/cc--such as AlSi10 Mg, AlSi12; [0041] Steel
Alloys .about.7.8 g/cc--such as Stainless Steel, Hot Worked Steel
(stainless and non stainless); [0042] Titanium .about.4.5
g/cc--Pure Ti, TiAl6V4, TiAl6V4 ELI; [0043] Silver .about.10.3
g/cc; [0044] Gold .about.19.3 g/cc; [0045] Tungsten .about.19.2
g/cc; [0046] Platinum .about.21.4 g/cc; [0047] Nickel Based Alloys
such as Inconel; [0048] Cobalt-Chrome Alloys such as CoCr; [0049]
Bronze; and [0050] TiAl--3.8.about.4.0 g/cc (titanium
Aluminide).
[0051] The manufacturing apparatus 200 may also include a heat
shield 230 between the electron beam 240 and the powder hopper(s)
245 to prevent melting of the powdered materials 255 prior to being
moved into the build tank 260. A rake 250 is provided to move
powdered material 255 into the build tank 250 as needed during the
manufacturing.
[0052] The electron beam 240 is moved across the surface of the
powdered material 255 in the build tank 260 based on the computer
model to form the club head on a layer by layer basis. As each
layer is formed, the club head rests on the start plate 265 and
build platform 260. As the club head is formed, the start plate 265
and a build platform 260 are moved downward to provide space form
successive layers and additional powdered material 255.
[0053] Though an electron beam 240 is used by the apparatus 200
shown in FIG. 2A, the present application is not limited to
electron beam based technologies and may include any additive layer
manufacturing method that uses powdered material and high-energy
beams (such as an electron beam or a laser).
[0054] Laser Beam Apparatus
[0055] Additionally, FIG. 2B is a diagram illustrating an additive
layer manufacturing apparatus 300 using a laser beam, which may be
used in a method according to an embodiment of the present
application. The additive layer manufacturing apparatus 300 using a
laser beam works in a similar manner to the apparatus 200 discussed
above. Specifically, the manufacturing apparatus 300 includes a
laser 305 that generates a laser beam 350. The generated laser beam
350 is directed at a scanner system 310 that redirects and controls
the laser beam 350 to scan the laser beam 350 across the surface of
a fabrication bed 315 filled with powdered material 325. Further,
adjacent to the fabrication powder bed 315, a powder delivery
system 320 is provided to add additional powder material 325 to the
fabrication bed 315 as needed. The powder deliver system 320
includes a powder tank 355 filled with powdered material 325, a
powder deliver piston 330 that moves upward to push powdered
material 325 upward and a roller 335 that directs powdered material
to the fabrication powder bed 315.
[0056] The scanner system 310 controls the laser beam 350 to move
the laser across the surface of the fabrication bed 315 based on
the computer model to form the object being fabricated 340, layer
by layer. As successive layers of the object 340 are formed, a
fabrication piston 345 is retracted downward to gradually lower the
object 340 and allow powdered material 325 to flow over the top of
the object 340 so that successive layers can be formed.
[0057] As with the electron beam apparatus 200 discussed above, a
wide variety of powdered materials can be used in the laser beam
additive layer manufacturing apparatus 300, including most metals
including titanium (Ti), Steel, Aluminum (Al), Titanium aluminum
alloys (Titanium Aluminide or TiAl), which generally cannot be cast
or welded. Thus, the example materials include the same materials
discussed above with respect to the electron beam apparatus 200
[0058] Example Structures
[0059] These additive layer manufacturing techniques allow
manufacturing of surface features having a minimum thickness of
Surfaces equal to 300 microns (um). Further, structures of mesh or
lattice structures such as those shown in FIGS. 3, 4, 8 and 9
discussed below may have a minimum thickness equal to 150 microns
(um).
[0060] In some embodiments, the golf head may be manufactured to
have a one piece (or unibody) construction, with the face and body
(crown, skirt, sole) being formed as a one-piece golf head having
hollow or partially hollow sections without a need to weld
components together. In some embodiments, a small exit hole may be
used to remove powder trapped within hollow areas of the head, but
the exit hole can be drilled after the head is manufactured.
[0061] Using the additive layer manufacturing techniques, any type
of golf club head could be theoretically manufactured based on a
generated computer model without a need to retool, producing a
variety of clubs faster than methods previously used, such as
casting, stamping or forging. Additionally, in some embodiments,
using additive layer manufacturing techniques may allow a reduction
in waste material because 95.about.98% of powder can be reclaimed
and used to make more parts. Conversely, forging and casting
processes typically produce significant amounts of waste
materials.
[0062] Additionally, additive layer manufacturing techniques may
not require welding of multiple pieces together because clubs can
have unibody construction to form a one-piece golf head having a
hollow and/or non-hollow sections with no welds. Further, as would
be apparent to a person of ordinary skill in the art, if welding is
not required, the occurrence of heat affected zones that degrade
material properties may be reduced.
[0063] The additive layer manufacturing process eliminates
thickness and weight variations often caused by grinding to remove
material, thermal expansions and shrinkage caused by the lost wax
casting process, and inconsistencies and tool wear with
conventional tooling processes.
[0064] As the additive layer manufacturing processes do not require
grinding, which may cause varying thickness or weak spots, tooling,
or welding, which may cause thermal expansion or shrinkage, tighter
tolerances can be held. These tighter tolerances may also be a
reduced need to "re-work" or "repair" out of spec. parts, which can
produce a cost savings.
[0065] Further, additive layer manufacturing processes may not
suffer Flow constraints that casting may experience. Further,
additive layer manufacturing processes have higher porosity
compared to casting (99.5% dense) and may produce more durable part
with thinner structures
[0066] Further, additive layer manufacturing techniques may allow
the manufacturing of complex geometries not achievable with
casting, machining, or forging techniques typically used. FIGS. 3-9
illustrate a sampling of the structures that can be manufactured
using additive layer manufacturing techniques.
[0067] For example, internal 3D geometries that cannot otherwise be
manufactured, such as those shown in embodiments (a)-(i) of FIG. 3,
may be manufactured. Further, undercuts such as those shown in
embodiment (j) of FIG. 3 may be formed without the need for special
tooling. Further, separate pockets and slots, typically too
difficult to cast or machine, such as those shown in embodiments
(k) and (l), can be manufactured using additive layer manufacturing
techniques. Thus, iron bodies/soles can be made with
undercuts/complex geometries can be manufactured.
[0068] Further, 3D lattice/core geometries having a thin skin of
metal on either side (1 side), both sides (sandwich), or without a
skin on either side (open core), such as those shown in FIG. 4 may
also be manufactured. Also, a thin non-metallic skin can also be
bonded or joined to the core. These 3D lattice/core geometries are
discussed in more detail with respect to FIGS. 8 and 9 below.
[0069] Additionally, face inserts have complex variations in face
thickness and face geometry, such as those shown in FIGS. 6 and 7
may be manufactured. Specifically, as shown in FIGS. 6 and 7, face
inserts having multiple regions of different discrete thicknesses
can be manufactured with the thickest regions being located at
different portions of the club face depending on design needs.
Further, face plates may have complex interior geometries having
lightweight cores or lattice structures between skins as shown in
FIG. 7 may be manufactured. Since no welding/grinding is necessary,
a minimum thickness necessary to have a maximum Coefficient of
Restitution can be manufactured, and the inserts still having
sufficient durability.
[0070] Further, these face inserts can be manufactured to be have
complex internal geometries using additive layer manufacturing
techniques and then welded to bodies formed using conventional
methods such as casting, stamping, or forging. These face inserts
can be custom made for based on the player's striking tendencies
(i.e. to have max thickness where the player consistently impacts
striking face and with thicknesses reducing to maximize the
Coefficient of Restitution.
[0071] Further, the additive layer manufacturing techniques is not
limited to manufacturing the club head and may also be used to
manufacture thin metal foils. These thin metal foils may be
manufactured and wrapped around on a composite or metal shaft
substrate to change or customize the performance characteristics
and/or add cosmetic effects to a golf shaft. FIG. 5a shows an
example embodiment of a thin-metal foil 505 and FIG. 5a shows the
thin-metal foil 505 wrapped around a shaft 510. Alternative, a
Lightweight lattice structure can be inserted into the hollow inner
diameter of the shaft to change the stiffness/performance of the
shaft.
[0072] As discussed above, complex 3D geometries or 3D lattices can
be manufactured as a weight efficient support structure or as a
lightweight supporting core for thin walls. FIG. 8 illustrates an
enlarged view of an embodiment having thin walls 805, 810 with a
plurality of supporting lattices 815 formed between the thin walls
805, 810. Further, FIG. 9 illustrates a plurality of types of 3D
lattice structures that can be manufactured using additive layer
manufacturing techniques. These include pyramidal lattices (a),
tetrahedral lattices (b), 3D-Kagome lattices (c), diamond textile
lattices (d), diamond collinear lattices (e), and A square
collinear lattices (f). These structural shapes may to increase
strength/stiffness, lower weight, and change or optimize the "feel"
of the club. The lattice geometries shown in the present
application are merely examples and embodiments of the present
application are not limited to these shapes. Further, the lattice
geometries may also include a 3D mesh designed and optimized to
provide the head characteristics desired based on the user's
needs.
[0073] These "lattice" geometries manufactured using additive layer
manufacturing techniques can be applied to any part of a golf club
head, including the sole, crown, skirt, etc. and is not
particularly limited to only the hitting face. These lattices can
also provide an internal support structure to join two sections
(for example can be a bridge between the crown and the sole to
provide stiffness). Further, the lattice geometries can be
manufactured separately or integrated into 1 piece heads.
[0074] Additive layer manufacturing can also allow the development
of any other details or shapes that have previously been too fine
to be cast or machined, such as springs and teeth of a snap clip
allowing components (weights) to be attached to an exterior of a
club head. The embodiments shown and discussed above are not
intended to be limited and are merely provided as examples.
[0075] Additionally, as additive layer manufactured golf club
components require minimal post manufacturing finishing, that may
reduce manufacturing cost or time. Further, additive layer
manufacturing discussed above can also allow the "printing" of a
surface finish or engineered texture on the face or any exterior
surface to influence spin, aerodynamics, or acoustics (sound).
[0076] After the heads and other club components are manufactured
and finished in action 130 of the FIG. 1, the heads are assembled
to the required shafts and grips to achieve the club specifications
(length, weight, flex, etc.) determined as optimal during the
fitting process in action 135. Thus, a final golf club is supplied
that is made specifically for the individual golfer based on his
unique player characteristics, and his unique requirements to give
optimal performance. The properties and parameters of the head
components are determined and manufactured to be customized to the
individual to a much greater extent that was previous
available.
[0077] Example Computing Device And Environment
[0078] FIG. 10 shows an example computing environment with an
example computing device suitable for implementing at least one
example implementation. Computing device 1005 in computing
environment 1000 can include one or more processing units, cores,
or processors 1010, memory 1015 (e.g., RAM or ROM), internal
storage 1020 (e.g., magnetic, optical, or solid state storage), and
I/O interface 1025, all of which can be coupled on a communication
mechanism or bus 1030 for communicating information.
[0079] Computing device 1005 can be communicatively coupled to
input/user interface 1035 and output device/interface 1040. Either
one or both of input/user interface 1035 and output
device/interface 1040 can be a wired or wireless interface and can
be detachable. Input/user interface 1035 may include any device,
component, sensor, or interface, physical or virtual that can be
used to provide input (e.g., keyboard, a pointing/cursor control,
microphone, camera, braille, motion sensor, optical reader, or the
like). Output device/interface 1040 may include a display, monitor,
printer, speaker, braille, or the like. In some example
implementations, input/user interface 1035 and output
device/interface 1040 can be embedded with or physically coupled to
computing device 1005 (e.g., a mobile computing device with buttons
or touch-screen input/user interface and an output or printing
display, or a television).
[0080] Computing device 1005 can be communicatively coupled to
external storage 1045 and network 1050 for communicating with any
number of networked components, devices, and systems, including one
or more computing devices of the same or different configuration.
Computing device 1005 or any connected computing device can be
functioning as, providing services of, or referred to as a server,
client, thin server, general machine, special-purpose machine, or
by other labels.
[0081] I/O interface 1025 can include, but is not limited to, wired
and/or wireless interfaces using any communication or I/O protocols
or standards (e.g., Ethernet, 802.11x, Universal System Bus, WiMax,
modem, a cellular network protocol, and the like) for communicating
information to and/or from at least all the connected components,
devices, and networks in computing environment 1000. Network 1050
can be any network or combination of networks (e.g., the Internet,
local area network, wide area network, a telephonic network, a
cellular network, satellite network, and the like).
[0082] Computing device 1005 can use and/or communicate using
computer-usable or computer-readable media, including transitory
media and non-transitory media. Transitory media include
transmission media (e.g., metal cables, fiber optics), signals,
carrier waves, and the like. Non-transitory media include magnetic
media (e.g., disks and tapes), optical media (e.g., CD ROM, digital
video disks, Blu-ray disks), solid state media (e.g., RAM, ROM,
flash memory, solid-state storage), and other non-volatile storage
or memory.
[0083] Computing device 1005 can be used to implement techniques,
methods, applications, processes, or computer-executable
instructions to implement at least one implementation (e.g., a
described implementation). Computer-executable instructions can be
retrieved from transitory media, and stored on and retrieved from
non-transitory media. The executable instructions can be originated
from one or more of any programming, scripting, and machine
languages (e.g., C, C++, C#, Java, Visual Basic, Python, Perl,
JavaScript, and others).
[0084] Processor(s) 1010 can execute under any operating system
(OS) (not shown), in a native or virtual environment. To implement
a described implementation, one or more applications can be
deployed that include logic unit 1060, application programming
interface (API) unit 1065, input unit 1070, output unit 1075,
design parameter determining unit 1080, club head modeling unit
1085, manufacturing controller 1090, and inter-unit communication
mechanism 1095 for the different units to communicate with each
other, with the OS, and with other applications (not shown). For
example, design parameter determining unit 1080, club head modeling
unit 1085, action unit 1090, along with one or more other units,
may implement one or more processes shown in FIGS. 1. In some
example implementations, design parameter determining unit 1080 may
include two or more separate units. The described units and
elements can be varied in design, function, configuration, or
implementation and are not limited to the descriptions
provided.
[0085] In some example implementations, when information or an
execution instruction is received by API unit 1065, it may be
communicated to one or more other units (e.g., logic unit 1060,
input unit 1070, output unit 1075, design parameter determining
unit 1080, club head modeling unit 1085, manufacturing controller
1090). For example, club head modeling unit 1085 may generate a
computer model of a club head based on design parameters determined
by the design parameter determining unit 1080 based on received
user's swing dynamics.
[0086] The design parameter determining unit 1080 may use the
inter-unit communication mechanism 1095 to receive a user's swing
dynamics input via the input unit 1070. Further, the design
parameter determining unit 1080 may determine club design
parameters based on the input user swing dynamics and may
communicate the club design parameters to the club head modeling
unit 1085. The club head modeling unit 1085 may generate computer
model of a golf club head based on the determined club design
parameters and communicate the computer model to the manufacturing
controller 1090. The manufacturing controller 1090 may use the
generated model to control additive layer manufacturing equipment
to manufacture a golf club head based on the received model.
[0087] In some examples, logic unit 1060 may be configured to
control the information flow among the units and direct the
services provided by API unit 1065, input unit 1070, output unit
1075, the design parameter determining unit 1080, club head
modeling unit 1085, manufacturing controller 1090 in order to
implement an implementation described above. For example, the flow
of one or more processes or implementations may be controlled by
logic unit 1060 alone or in conjunction with API unit 1065.
[0088] Although a few example implementations have been shown and
described, these example implementations are provided to convey the
subject matter described herein to people who are familiar with
this field. It should be understood that the subject matter
described herein may be embodied in various forms without being
limited to the described example implementations. The subject
matter described herein can be practiced without those specifically
defined or described matters or with other or different elements or
matters not described. It will be appreciated by those familiar
with this field that changes may be made in these example
implementations without departing from the subject matter described
herein as defined in the appended claims and their equivalents.
[0089] The above description of the disclosed embodiments is
provided to enable any person skilled in the art to make or use the
invention. Various modifications to these embodiments will be
readily apparent to those skilled in the art, and the generic
principles described herein can be applied to other embodiments
without departing from the spirit or scope of the invention. Thus,
it is to be understood that the description and drawings presented
herein represent a presently preferred embodiment of the invention
and are therefore representative of the subject matter which is
broadly contemplated by the present invention. It is further
understood that the scope of the present invention fully
encompasses other embodiments that may become obvious to those
skilled in the art and that the scope of the present invention is
accordingly not limited.
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