Methods of creating golf club components with complex structures that would be difficult, impossible, or cost prohibitive to produce, such as lattice structures, beam structures, and complex surface-based structures, are described herein. In particular, a binder jet machine is used create complex structures to optimize weighting, sound, and performance of golf club heads. The method preferably includes the steps of designing a golf club head component in CAD using optimization software, printing the component from a powdered material, and then removing excess powder from the component via port holes that extend into an external surface of the component and communicate with interior voids within the component.

Methods for removing support structures in additively manufactured parts are disclosed. A method in accordance with an aspect of the present disclosure comprises inserting a demolition object in a first state into a hollow portion of a 3-D printed part, breaking a support structure within the hollow portion by contact with the demolition object, changing the demolition object into a second state while the demolition object is within the hollow portion of the 3-D printed part, and removing the demolition object from the hollow portion of the 3-D printed part.

Methods for removing support structures in additively manufactured parts are disclosed. A method in accordance with an aspect of the present disclosure comprises inserting a demolition object in a first state into a hollow portion of a 3-D printed part, breaking a support structure within the hollow portion by contact with the demolition object, changing the demolition object into a second state while the demolition object is within the hollow portion of the 3-D printed part, and removing the demolition object from the hollow portion of the 3-D printed part.

A method for the dry filtration of a gas flow carrying foreign objects, a filter device for cleaning off waste gas resulting from additive manufacturing technologies, comprises feeding a raw gas flow containing foreign objects into a raw gas space of a filter unit having at least one filter surface separating a raw gas side from a clean gas side; feeding oxidant to a reaction region located on the raw gas side of the filter surface downstream of the filter surface; such that foreign objects contained in material cleaned off from the filter surface and/or in the raw gas flow react with the oxidant in the reaction region to form oxide-containing foreign objects.

A method for the dry filtration of a gas flow carrying foreign objects, a filter device for cleaning off waste gas resulting from additive manufacturing technologies, comprises feeding a raw gas flow containing foreign objects into a raw gas space of a filter unit having at least one filter surface separating a raw gas side from a clean gas side; feeding oxidant to a reaction region located on the raw gas side of the filter surface downstream of the filter surface; such that foreign objects contained in material cleaned off from the filter surface and/or in the raw gas flow react with the oxidant in the reaction region to form oxide-containing foreign objects.

A method of fabricating a near net shape component includes forming a sacrificial shell from a pulverant material using an additive manufacturing process, the shell having an aperture. The method further includes filling the shell with a second pulverant material, subjecting the filled shell to a consolidation process, and removing the shell from the consolidated second pulverant material.

A method of fabricating a near net shape component includes forming a sacrificial shell from a pulverant material using an additive manufacturing process, the shell having an aperture. The method further includes filling the shell with a second pulverant material, subjecting the filled shell to a consolidation process, and removing the shell from the consolidated second pulverant material.

A cleaning device 2 is for performing a preliminary cleaning step 110 to a cleaning step 120 of a cleaning method 100, and includes a preliminary cleaning tank 11 containing a preliminary cleaning agent LQ1, a cleaning tank 12 containing a cleaning agent LQ2, an outer container 21 containing the preliminary cleaning tank 11 and the cleaning tank 12, a temperature adjustment unit 30 for adjusting the temperature of water WT contained in the outer container 21, an ultrasonic unit 40 for applying an ultrasonic wave to the water WT, or to the preliminary cleaning agent LQ1 or the cleaning agent LQ2 through the preliminary cleaning tank 11 or the cleaning tank 12, and a controller 80 controlling each of the units.

A cleaning device 2 is for performing a preliminary cleaning step 110 to a cleaning step 120 of a cleaning method 100, and includes a preliminary cleaning tank 11 containing a preliminary cleaning agent LQ1, a cleaning tank 12 containing a cleaning agent LQ2, an outer container 21 containing the preliminary cleaning tank 11 and the cleaning tank 12, a temperature adjustment unit 30 for adjusting the temperature of water WT contained in the outer container 21, an ultrasonic unit 40 for applying an ultrasonic wave to the water WT, or to the preliminary cleaning agent LQ1 or the cleaning agent LQ2 through the preliminary cleaning tank 11 or the cleaning tank 12, and a controller 80 controlling each of the units.

Various embodiments provide a method of additively manufacturing a part including depositing a layer of a powder on a working surface, depositing a binder solution on the layer of the powder at first locations, and depositing a sintering aid solution on the layer of the powder at second locations. The sintering aid solution comprises a sintering aid in a solvent. In various embodiments, the sintering aid enables an increased brown strength as compared to parts containing unbound powder. The method enables binders that provide high green strength to be used at the edges of the part, while also balancing a shortened debind time with an increased brown strength. Embodiments in which binder solution is deposited according to a predetermined pattern at second locations are also described.