A co-forged iron type golf club is disclosed. More specifically, the present invention discloses a co-forged iron type golf club with the body portion made out of a first material and at least one weight adjustment portion monolithically encased within the body portion of the co-forged iron type golf club head without the need for secondary attachment or machining operations. The present invention creates of an iron type golf club head from a pre-form billet that already contains two or more materials before the actual forging process resulting in a multi-material golf club head that doesn't require any post manufacturing operations such as machining, welding, swaging, gluing, and the like.

A co-forged iron type golf club is disclosed. More specifically, the present invention discloses a co-forged iron type golf club with the body portion made out of a first material and at least one weight adjustment portion monolithically encased within the body portion of the co-forged iron type golf club head without the need for secondary attachment or machining operations. The present invention also includes a combination internal cavities and weight adjustment portions that improve the inertial and performance attributes of the iron type golf club head.

Methods of manufacturing a golf club head with one or more stiffening members proximate the face, and particularly solid rods or a plate with one or more cutouts, is disclosed herein. One method includes the steps of preparing a wax mold of a golf club head including a plate stiffening member with excess material, casting the golf club head, and machining away the excess material. Another method includes the steps of casting a golf club body, providing a plate stiffening member, providing a face component such as a face cup, tack welding the plate stiffening member and the face component to the golf club body, and welding these parts together.

Methods of manufacturing a golf club head with one or more stiffening members proximate the face, and particularly solid rods or a plate with one or more cutouts, is disclosed herein. One method includes the steps of preparing a wax mold of a golf club head including a plate stiffening member with excess material, casting the golf club head, and machining away the excess material. Another method includes the steps of casting a golf club body, providing a plate stiffening member, providing a face component such as a face cup, tack welding the plate stiffening member and the face component to the golf club body, and welding these parts together.

A method of manufacturing a golf club head having a plurality of structural connectors, and particularly solid rods proximate the face, is disclosed. The method includes the steps of preparing a wax of a golf club head body, the body having first and second through-holes, a hollow interior, and first and second receiving pockets, preparing waxes of first and second solid rods, inserting the first solid rod wax into the first through-hole and seating its lower end in the first receiving pocket, inserting the second solid rod wax into the second through-hole and seating its lower end in the second receiving pocket, bonding each of the first and second solid rods to the body with an adhesive material to form a combined wax mold, and casting a golf club head from the combined wax mold.

A method of manufacturing a golf club head having a plurality of structural connectors, and particularly solid rods proximate the face, is disclosed. The method includes the steps of preparing a wax of a golf club head body, the body having first and second through-holes, a hollow interior, and first and second receiving pockets, preparing waxes of first and second solid rods, inserting the first solid rod wax into the first through-hole and seating its lower end in the first receiving pocket, inserting the second solid rod wax into the second through-hole and seating its lower end in the second receiving pocket, bonding each of the first and second solid rods to the body with an adhesive material to form a combined wax mold, and casting a golf club head from the combined wax mold.

A forged golf club face has a continuous outer layer of a first material encasing at least one inner layer made of second material. The materials may have differing properties, such as Young's Modulus, density, and strength properties, among others. By incorporating the different materials into the outer layer and the inner layer, the coefficient of restitution (COR) of the golf club face is improved without sacrificing durability. The club face is forged from a pre-formed billet having at least one monolithically encased inner layer.

A forged golf club face has a continuous outer layer of a first material encasing at least one inner layer made of second material. The materials may have differing properties, such as Young's Modulus, density, and strength properties, among others. By incorporating the different materials into the outer layer and the inner layer, the coefficient of restitution (COR) of the golf club face is improved without sacrificing durability. The club face is forged from a pre-formed billet having at least one monolithically encased inner layer.

A method for forming a golf club head includes steps of preparing a cylindrical metal blank, heating the metal blank to become softened, shaping the metal blank by pressing and pushing the metal blank forward on a shaping die with a pushing unit to form a head section and an engagement section extending outwards from the head section, and stamping the head section of the metal blank when the metal blank still has residual heat to shape the head section into a golf club head having two opposite surfaces. A bending step can be executed before or after the stamping step to bend the engagement section. Therefore, the method simplifies the processing procedures greatly, achieves a quick shaping operation, decreases residual materials and processing costs, and increases an economic benefit.

A method for forming a golf club head includes steps of preparing a cylindrical metal blank, heating the metal blank to become softened, shaping the metal blank by pressing and pushing the metal blank forward on a shaping die with a pushing unit to form a head section and an engagement section extending outwards from the head section, and stamping the head section of the metal blank when the metal blank still has residual heat to shape the head section into a golf club head having two opposite surfaces. A bending step can be executed before or after the stamping step to bend the engagement section. Therefore, the method simplifies the processing procedures greatly, achieves a quick shaping operation, decreases residual materials and processing costs, and increases an economic benefit.