Golf balls and golf ball components made using three-dimensional (3D) additive manufacturing systems are provided. The golf ball includes at least one three-dimensional piece. Preferably, a continuous liquid interface printing method is used to make the three-dimensional structure. Ultraviolet (UV)-light polymerizable materials are used in the method. The method may be used to make single-piece or multi-piece balls. For example, the ball may include an inner core produced by the liquid interface printing method. An outer core layer may be disposed about the inner core, and a cover comprising inner and outer cover layers may encapsulate the core assembly to form the finished golf ball. The outer core and cover layers may be made using conventional molding technologies or the methods of this invention.

Multi-piece golf balls having a solid core and cover are provided. The ball contains a small, heavy inner core and surrounding outer core layer. The inner core preferably contains metal powder such as copper, steel, brass, tungsten, titanium, nickel, iron, tin, and bronze particles dispersed in a thermoset or thermoplastic polymeric matrix. For example, a polybutadiene rubber matrix may be used. In one preferred embodiment, the inner core contains elemental iron powder. Preferably, the particles have a weight average size in the range of about 10 m to about 450 m. In one embodiment, the outer surface of the inner core has a structure with projecting members. For example, the outer surface may contain multiple projecting ribs with gaps located between the ribs. The ball includes a cover surrounding the core structure. The cover may be multi-layered.

A golf ball has a main body 12 and a paint layer 10 positioned outside the main body 12. The main body 12 has a plurality of minute projections 18 on a surface thereof. The paint layer 10 has a thickness Tp of not less than 5 m and not greater than 30 m. Each minute projection 18 is embedded in the paint layer 10. An average value Hav of heights H of the minute projections 18 is not less than 0.5 m and not greater than 80% of the thickness Tp. A ratio Pp of a sum of areas of all the minute projections 18 to a surface area of a phantom sphere of the golf ball is not less than 7%. An average value Dav of diameters D of the minute projections 18 is not less than 5 m and not greater than 50 m.

A golf ball has a main body 12 and a paint layer 10 positioned outside the main body 12. The main body 12 has a plurality of minute projections 18 on a surface thereof. The paint layer 10 has a thickness Tp of not less than 5 m and not greater than 30 m. Each minute projection 18 is embedded in the paint layer 10. An average value Hav of heights H of the minute projections 18 is not less than 0.5 m and not greater than 80% of the thickness Tp. A ratio Pp of a sum of areas of all the minute projections 18 to a surface area of a phantom sphere of the golf ball is not less than 7%. An average value Dav of diameters D of the minute projections 18 is not less than 5 m and not greater than 50 m.

Multi-piece golf balls having a solid core and cover are provided. The ball contains a small, heavy inner core and surrounding outer core layer. The inner core preferably contains metal powder such as copper, steel, brass, tungsten, titanium, nickel, iron, tin, and bronze particles dispersed in a thermoset or thermoplastic polymeric matrix. For example, a polybutadiene rubber matrix may be used. In one preferred embodiment, the inner core contains elemental iron powder. Preferably, the particles have a weight average size in the range of about 10 m to about 450 m. In one embodiment, the outer surface of the inner core has a structure with projecting members. For example, the outer surface may contain multiple projecting ribs with gaps located between the ribs. The ball includes a cover surrounding the core structure. The cover may be multi-layered.

Golf balls comprising a multi-layer core and a cover are disclosed. The multi-layer core comprises at least three layers, including at least one thermoset layer and at least one thermoplastic layer. At least one core layer has a plurality of projections disposed thereon.

Multi-layered, golf balls having a core made of a foamed composition are provided. The core preferably has a foam inner core (center) and surrounding thermoset or thermoplastic outer core layer. The core also includes a structural insert such as, for example, a solid shell, perforated shell, a lattice or mesh, or a central hub with extending arms, and the like. The core layers have different hardness gradients and specific gravity values. The ball further includes a cover having at least one layer. By adjusting the respective specific gravity values of the core layers, the Moment of Inertia (MOI) of the ball can be increased or decreased. In one embodiment, the ball has generally good flight distance and low spin rate.

Multi-piece golf balls having a solid core and cover are provided. The ball contains a small, heavy inner core and surrounding outer core layer. The inner core preferably contains metal powder such as copper, steel, brass, tungsten, titanium, nickel, iron, tin, and bronze particles dispersed in a thermoset or thermoplastic polymeric matrix. For example, a polybutadiene rubber matrix may be used. In one preferred embodiment, the inner core contains elemental iron powder. Preferably, the particles have a weight average size in the range of about 10 m to about 450 m. In one embodiment, the outer surface of the inner core has a structure with projecting members. For example, the outer surface may contain multiple projecting ribs with gaps located between the ribs. The ball includes a cover surrounding the core structure. The cover may be multi-layered.

Golf balls and golf ball components made using three-dimensional (3D) additive manufacturing systems are provided. The golf ball includes at least one three-dimensional piece. Preferably, a continuous liquid interface printing method is used to make the three-dimensional structure. Ultraviolet (UV)-light polymerizable materials are used in the method. The method may be used to make single-piece or multi-piece balls. For example, the ball may include an inner core produced by the liquid interface printing method. An outer core layer may be disposed about the inner core, and a cover comprising inner and outer cover layers may encapsulate the core assembly to form the finished golf ball. The outer core and cover layers may be made using conventional molding technologies or the methods of this invention.

Multi-layered, golf balls having a core made of a foamed composition are provided. The core preferably has a foam inner core (center) and surrounding thermoset or thermoplastic outer core layer. The core also includes a structural insert such as, for example, a solid shell, perforated shell, a lattice or mesh, or a central hub with extending arms, and the like. The core layers have different hardness gradients and specific gravity values. The ball further includes a cover having at least one layer. By adjusting the respective specific gravity values of the core layers, the Moment of Inertia (MOI) of the ball can be increased or decreased. In one embodiment, the ball has generally good flight distance and low spin rate.