Bent composite golf club shaft and methods for manufacturing bent composite golf club shafts

A method of manufacturing a golf club shaft comprising the steps of:

• cutting composite material into a plurality of composite pieces;
• engaging a flexible core with a rod composed of a rigid material;
• wrapping the composite pieces around the flexible core and rod combination to form a first precursor shaft;
• rolling the first precursor shaft to form a straight, second precursor shaft;
• wrapping tape around the second precursor shaft;
• partially curing the second precursor shaft to form a third precursor shaft with a tip;
• removing the flexible core and rod combination from the third precursor shaft;
• placing a bladder in the third precursor shaft and inflating the bladder;
• placing the tip in a forming mold while the tip is at a temperature above Tg;
• bending the tip within the forming mold to form a fourth precursor shaft with a first bend having a first bend angle of 20 to 25 degrees relative to the non-tip shaft;
• bending the tip within the forming mold to form the fourth precursor shaft with a second bend having a second bend angle of 12 to 16 degrees relative to the first bend angle;
• curing the fourth precursor shaft;
• removing the flexible core and rod combination from the fourth precursor shaft;
• and
• applying cosmetic features to the fourth precursor shaft to create the final golf club shaft.