Forged iron head

A method for forming an iron-type golf club head comprising:

• providing a main club body, an insert, a cap, and a weight;
• wherein the main club body comprises:
• a front, a rear, a toe end, a heel end, a strikeface, a strikeface front surface configured to impact a golf ball, a hosel configured to receive a golf shaft, a top-rail, a sole, a strikeface rear surface, and a perimeter sidewall formed by the top rail, the sole, the toe end and the heel end;
• wherein the perimeter sidewall extends rearwardly generally perpendicular to the strikeface;
• wherein a back cavity is defined by the perimeter sidewall and the strikeface rear surface;
• and
• wherein the back cavity is open toward the rear of the main club body;
• wherein the perimeter sidewall further comprises a locking groove recessed into the perimeter sidewall at least partially surrounding the strikeface rear surface;
• wherein the locking groove is recessed into the perimeter sidewall in a direction parallel to the strikeface rear surface offset rearwardly from the strikeface rear surface;
• wherein the main club body comprises an aperture in the heel end such that the aperture is a hole open to a heel end outer surface and also open to the back cavity;
• wherein the main club body further comprises a first material having a first density;
• wherein the first material comprises a first metallic alloy;
• providing a squeeze casting mold;
• placing the main club body within a squeeze casting mold such that the back cavity is exposed to an interior of the squeeze casting mold;
• inserting a pull rod through the aperture into the back cavity;
• heating a second metallic alloy material to a plastic temperature and forcing the second material into the squeeze casting mold to form the lightweight insert within the back cavity of the main club body;
• wherein the second material having a second density lower than the first density;
• opening the squeeze cast mold, and withdrawing the pull rod out through the aperture, thereby forming a void in the lightweight insert;
• receiving a weight within the void through the aperture;
• sealing the aperture with the cap.

A method for forming an iron-type golf club head comprising:

• providing a main club body, an insert, a cap, and a weight;
• wherein the main club body comprises:
• a front, a rear, a toe end, a heel end, a strikeface, a strikeface front surface configured to impact a golf ball, a hosel configured to receive a golf shaft, a top-rail, a sole, a strikeface rear surface, and a perimeter sidewall formed by the top rail, the sole, the toe end and the heel end;
• wherein the perimeter sidewall extends rearwardly generally perpendicular to the strikeface;
• wherein a back cavity is defined by the perimeter sidewall and the strikeface rear surface;
• and
• wherein the back cavity is open toward the rear of the main club body;
• wherein the perimeter sidewall further comprises a locking groove recessed into the perimeter sidewall at least partially surrounding the strikeface rear surface;
• wherein the locking groove is recessed into the perimeter sidewall in a direction parallel to the strikeface rear surface offset rearwardly from the strikeface rear surface;
• wherein the main club body comprises an aperture in the heel end such that the aperture is a hole open to a heel end out surface and also open to the back cavity;
• wherein the main club body further comprises a first material having a first density;
• wherein the first material comprises a first metallic alloy;
• providing a plastic injection mold;
• placing the main club body within a plastic injection mold such that the back cavity is exposed to an interior of the plastic injection mold;
• inserting a pull rod through the aperture into the back cavity;
• heating a thermoplastic material and forcing the thermoplastic material into the plastic injection mold to form the lightweight insert within the back cavity of the main club body;
• wherein the second material having a second density lower than the first density;
• opening the plastic injection mold, and withdrawing the pull rod out through the aperture, thereby forming a void in the lightweight insert;
• receiving a weight within the void through the aperture;
• sealing the aperture with the cap.