A device (e.g., an article of athletic gear) comprising a post-molded expandable component, which is a part of the device that is configured to be expanded or has been expanded after being molded. This may allow the post-molded expandable component to have enhanced characteristics (e.g., be more shock-absorbent, lighter, etc.), to be cost-effectively manufactured (e.g., by using less material and/or making it in various sizes), and/or to be customized for a user (e.g., by custom-fitting it to the user).

A device (e.g., an article of athletic gear) comprising a post-molded expandable component, which is a part of the device that is configured to be expanded or has been expanded after being molded. This may allow the post-molded expandable component to have enhanced characteristics (e.g., be more shock-absorbent, lighter, etc.), to be cost-effectively manufactured (e.g., by using less material and/or making it in various sizes), and/or to be customized for a user (e.g., by custom-fitting it to the user).

A golf club with a multi-material face is disclosed herein. More specifically, the golf club head in accordance with the present invention has a multi-material striking face portion that is made out of a backing layer having a frontal pocket, made out of titanium, and an insert, made out of a composite material, adapted to be inserted into the frontal pocket. The frontal pocket and the insert could have complementary dovetail shaped undercut features to create a mechanical bond between these two components. The insert may be bonded to the frontal pocket using an adhesive impregnated within a glass fiber weave.

A golf club with a multi-material face is disclosed herein. More specifically, the golf club head in accordance with the present invention has a multi-material striking face portion that is made out of a backing layer having a frontal pocket, made out of titanium, and an insert, made out of a composite material, adapted to be inserted into the frontal pocket. The frontal pocket and the insert could have complementary dovetail shaped undercut features to create a mechanical bond between these two components.

A method of forming a device of composite material includes providing a mold having an internal space forming a cavity with an inner surface, the cavity having a shape corresponding to an inner shape of the device to be formed, placing inserts at one or more pre-defined positions along the inner surface, holding the inserts at the one or more positions, introducing removable material into the cavity of the mold to form a pattern having the inserts fixed therein when the removable material is in solid form, and removing the pattern having the inserts fixed therein from the mold.

Wood-type golf clubs and/or golf club heads include: (a) a golf club head base member including a face member having a ball striking face; and (b) a polymeric body member engaged with the golf club head base member, wherein the polymeric body member is formed via a rotational molding process (or other centrifugal force inducing molding process) and/or engaged with the golf club head base member via a rotational molding process (or other centrifugal force inducing molding process). The polymeric body member forms at least a portion of a crown member of the club head in some structures.

A composite golf club head and a method for manufacturing the same are provided. The composite golf club head has a carbon fiber composite body and a striking face. The carbon fiber composite body is formed by multiple carbon fiber prepreg materials or multiple composite prepreg materials including carbon fiber with stacking, a positive pressure, a vacuum negative pressure, and heating. The striking face is made of a carbon fiber composite or metal material, and is fixedly glued to a front opening portion of the carbon fiber composite body. A weight of the carbon fiber composite body is reduced. Center of gravity and moment of inertia can be adjusted easily according to striking distances or feel of striking of different golf club heads for enhancing a striking performance of the composite golf club head.

A golf club head includes a club face and a body. The club face is formed from a metallic material and includes a first, hitting surface, a second, rear surface that is opposite the first surface, and a flange that is separated from the second surface by a transverse distance. The body is formed from a polymeric material and includes a crown, a sole, a hosel, and a face support. The club face and the body cooperate to define a closed volume, and the face support extends to opposing sides of the flange and is operative to couple the club face to the body.

A golf club head includes a face, a club head body, and a hosel. The hosel has a tubular hosel body extending along a longitudinal axis and defining a bore. The bore is configured to receive a golf club shaft or a shaft adapter. The tubular hosel body is molded from a polymeric material that includes a resin and a plurality of fibers, each fiber has a length of from about 0.01 mm to about 12 mm.

A method for manufacturing a striking plate of a golf club head includes the steps of: a sewing step, in which at least one roving material is sewn onto a base material so as to form a laminate blank with an uneven thickness in a normal direction of the base material; and a forming step, in which the laminate blank is placed in a mold cavity of a mold and is formed into the striking plate with an uneven thickness.