# US 2026/0061698 A1 · Systems and methods for additive manufacturing of a golf club > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2026/0061698 A1 - Document ID: US20260061698A1 - Status: Published application - Kind: A1 - Application number: 19/377,686 - Filed: 2025-11-03 - Published: 2026-03-05 - Earliest claimed: 2020-04-17 - Assignees: Cobra Golf Incorporated - Applicants: Cobra Golf Incorporated - Inventors: Ryan L. Roach; Cameron J. Day; Bryce W. Hobbs - Web page: https://patentgrep.com/patent/US20260061698A1 ## CPC - B29C 64/153: using layers of powder being selectively joined, e.g. by selective laser sintering or melting - A63B 53/04: Heads - A63B 53/0475: {with one or more enclosed cavities} - A63B 53/0487: {for putters (A63B53/065 takes precedence)} - B22F 5/10: of articles with cavities or holes, not otherwise provided for in the preceding subgroups - B22F 10/14: by jetting of binder onto a bed of metal powder - B22F 10/38: to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures - B22F 10/40: Structures for supporting workpieces or articles during manufacture and removed afterwards - B22F 10/68: Cleaning or washing - B33Y 40/20: Post-treatment, e.g. curing, coating or polishing - A63B 2053/0491: {with added weights, e.g. changeable, replaceable} - B22F 2998/10: Processes characterised by the sequence of their steps - B29C 64/40: Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof - B29L 2031/5227: {Clubs} - B33Y 10/00: Processes of additive manufacturing - B33Y 80/00: Products made by additive manufacturing - Y02P 10/25: Process efficiency - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - A63B: APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT (apparatus for passive exercising, massage A61H) - B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER - B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract A process of manufacturing a golf club component includes the step of spreading a layer of powdered material over a build plane defined over a build platform. Another step includes bonding, using an energy source, portions of the layer of powdered material. A different step includes repeating the spreading and bonding until the golf club component is formed. The process further includes the step of extracting loose powdered material from the golf club component. The build plane is offset from a ground plane between about 5 degrees and about 160 degrees. The ground plane is defined as a horizontal plane parallel to the ground when the golf club component is at address, and the build plane is not a face angle of the golf club component. ## Claims ### Claim 1 A process of manufacturing a golf club component, comprising: spreading a layer of powdered material over a build plane defined over a build platform; bonding, using an energy source, portions of the layer of powdered material, wherein the spreading and bonding are repeated until the golf club component is formed; and extracting loose powdered material from the golf club component, wherein the build plane is offset from a ground plane by between about 5 degrees and about 160 degrees, wherein the ground plane is defined as a horizontal plane parallel to the ground when the golf club component is at address, and wherein the build plane is not a face angle of the golf club component. ### Claim 2 (depends on 1) The process of manufacturing the golf club component of claim 1, wherein the golf club component comprises a segmented structure that is integrally formed with a body of the golf club component and extends from at least one internal surface of the golf club component. ### Claim 3 (depends on 2) The process of manufacturing the golf club component of claim 2, wherein at least a portion of the segmented structure is externally visible. ### Claim 4 (depends on 1) The process of manufacturing the golf club component of claim 1, wherein the energy source is in the form of a laser beam, an electron beam, or ultrasonic energy. ### Claim 5 A process of manufacturing a golf club component, comprising: spreading a layer of powdered material over a build plane defined over a build platform; depositing a binding agent over portions of the layer of powdered material, wherein the spreading and depositing are repeated until the golf club component is formed; sintering the golf club component; and extracting loose powdered material from the golf club component, wherein the build plane is offset from a ground plane by between about 5 degrees and about 160 degrees, wherein the ground plane is defined as a horizontal plane parallel to the ground when the golf club component is at address, and wherein the build plane is not a face angle of the golf club component. ### Claim 6 (depends on 5) The process of manufacturing the golf club component of claim 5, wherein the golf club component comprises a segmented structure, wherein the segmented structure includes a plurality of segments, wherein the segmented structure defines a segmented plane along which the plurality of segments extend, and wherein the segmented plane is offset with respect to the build plane and the ground plane. ### Claim 7 (depends on 5) The process of manufacturing the golf club component of claim 5, wherein the golf club component includes a segmented structure that is externally visible. ### Claim 8 (depends on 6) The process of manufacturing the golf club component of claim 6, wherein the segmented structure varies in one or more of unit cell type, unit cell geometry, unit cell size, segment thickness, segment volume, and unit cell density at one or more locations along the segmented structure. ### Claim 9 (depends on 5) The process of manufacturing the golf club component of claim 5, further comprising de-binding the golf club component to remove the binding agent. ### Claim 10 (depends on 5) The process of manufacturing the golf club component of claim 5, wherein the golf club component is a golf club head including a body, wherein the body includes a topline, a sole, and a front face, and wherein the body further defines a hosel configured to receive a shaft. ### Claim 11 A process of manufacturing a solid portion of a golf club head, comprising: spreading a layer of powdered material over a build plane defined over a build platform; bonding, using an energy source, portions of the layer of powdered material, wherein the spreading and binding are repeated until the solid portion of the golf club head is formed of sintered material; and removing a portion of the sintered material from the solid portion of the golf club head, wherein the build plane is offset from a ground plane between about 5 degrees and about 160 degrees, wherein the ground plane is defined as a horizontal plane parallel to the ground when the golf club head is at address, wherein the build plane is not a face angle of the golf club head, and wherein the golf club head comprises: a front face extending across a front side from a toe region through a medial region to a heel region, a topline extending laterally along a top side in a heel-toe direction, a sole extending laterally along a bottom side in a heel-toe direction, and a hosel. ### Claim 12 (depends on 11) The process of manufacturing the golf club head of claim 11, wherein the energy source is in the form of a laser beam, an electron beam, or ultrasonic energy. ### Claim 13 (depends on 11) The process of manufacturing the golf club head of claim 11, wherein the solid portion defines an aperture extending laterally into and through the solid portion, wherein the aperture has an outer edge disposed entirely within the toe region and rearwardly of the front side. ### Claim 14 (depends on 11) The process of manufacturing the golf club head of claim 11, wherein removing comprises machining the golf club head via milling or turning to obtain a finished characteristic that is at least one of a loft, a lie, a weight, a dimension, a volume, or a shape. ### Claim 15 A golf club including a golf club head formed by an additive manufacturing process, the golf club head comprising: a front side, a rear side, a bottom side, a top side, a toe side, and a heel side; a body that defines a toe region, a heel region, and a medial region between the toe region and the heel region; a first plane that extends orthogonal to a ground plane and separates the toe region from the medial region, wherein the ground plane is defined as a horizontal plane parallel to the ground when the golf club head is at address; a second plane that extends orthogonal to the ground plane and separates the heel region from the medial region; a front face that extends along the front side from the toe region, through the medial region, and into the heel region, wherein the front face is formed of sintered material by the additive manufacturing process; a topline extending laterally in a heel-toe direction along the top side; a sole extending laterally in the heel-toe direction along the bottom side; a plurality of grooves disposed on the front face; a toe portion that is defined between a distal end of the toe side and the first plane; a heel portion that is defined between a distal end of the heel side and the second plane; a hosel that is configured to receive a shaft; an internal cavity within the golf club head; and an aperture that is in fluid communication with the internal cavity. ### Claim 16 (depends on 15) The golf club of claim 15, wherein the front face is welded around a periphery of the front side of the body to enclose the internal cavity. ### Claim 17 (depends on 15) The golf club of claim 15, wherein the hosel defines a hosel cavity and the aperture is in fluid communication with the hosel cavity. ### Claim 18 (depends on 15) The golf club of claim 15, wherein the aperture is formed in the rear side. ### Claim 19 (depends on 15) The golf club of claim 15, wherein the aperture is formed in the toe side. ### Claim 20 (depends on 15) The golf club of claim 15, further comprising a weight element made of tungsten. ### Claim 21 (depends on 20) The golf club of claim 20, wherein the weight element is within the aperture. ### Claim 22 (depends on 15) The golf club of claim 15, further comprising a plurality of segments that extend from an internal surface of the body and define at least one intersection. ### Claim 23 A golf club including a golf club head formed by an additive manufacturing process, the golf club head comprising: a front side, a rear side, a bottom side, a top side, a toe side, and a heel side; a body that defines a toe region, a heel region, and a medial region between the toe region and the heel region, wherein the body is formed of sintered material by the additive manufacturing process; a first plane that extends orthogonal to a ground plane and separates the toe region from the medial region, wherein the ground plane is defined as a horizontal plane parallel to the ground when the golf club head is at address; a second plane that extends orthogonal to the ground plane and separates the heel region from the medial region; a front face that extends along the front side from the toe region, through the medial region, and into the heel region; a topline extending laterally in a heel-toe direction along the top side; a sole extending laterally in the heel-toe direction along the bottom side; a plurality of grooves disposed on the front face; a toe portion that is defined between a distal end of the toe side and the first plane; a heel portion that is defined between a distal end of the heel side and the second plane; a hosel that is configured to receive a shaft; an internal cavity within the golf club head; and an aperture that is in fluid communication with the internal cavity. ### Claim 24 (depends on 23) The golf club of claim 23, wherein the front face is welded around a periphery of the front side of the body to enclose the internal cavity. ### Claim 25 (depends on 23) The golf club of claim 23, wherein the hosel defines a hosel cavity and the aperture is in fluid communication with the hosel cavity. ### Claim 26 (depends on 23) The golf club of claim 23, wherein the aperture is formed in the rear side. ### Claim 27 (depends on 23) The golf club of claim 23, wherein the aperture is formed in the toe side. ### Claim 28 (depends on 23) The golf club of claim 23, further comprising a weight element made of tungsten. ### Claim 29 (depends on 28) The golf club of claim 28, wherein the weight element is within the aperture. ### Claim 30 (depends on 23) The golf club of claim 23, further comprising a plurality of segments disposed within the internal cavity, wherein the plurality of segments extend from an internal surface of the body.