Manufacturing A Golf Club Driver Head : Forged Versus Cast

The forged head derives its name from the use of a 500 ton press in its production process. Actually forged heads are made by cutting and stamping a sheet of titanium sheet into several different parts of the driver, and then welded together with an Arc welder. The most common construction is a 4-piece body, under which the driver head is made up of the crown, sole plate, face and hosel. The main advantage of the stamping process is low production cost. The disadvantages are limited dimensional accuracy; the long welding line inside the titanium driver head makes perimeter weighting difficult, the exact location of center of gravity difficult.

The cast Ti driver usually has a 2-piece body: The main body and the club face, where the face is attached to the body by welding. The benefits of investment casting are thinner wall thickness, complex geometry, reproducibility and dimensional accuracy. The main disadvantage is the much higher production costs. Almost all top of the line name brand titanium drivers were cast titanium driver heads. However due to lower retail prices there is trend that some brand name OEM driver heads are nowadays also forged titanium.

There are some titanium driver heads available offering both: lower price and design advantages of cast titanium drivers:

The new integra driver head from Integra Golf is a 3-piece construction featuring an innovative forging process that the crown plate and a beta-titanium face are forged from one piece. By forging the top plate and an ultra thin yet super strong beta titanium face (U.S. and Japan Patent Pending process) from one piece, a welding line is saved. The result is saving 25 gram or over 12% of the head's weight.

Integra Golf is manufacturing all their driver heads with innovative Cup Face Design. Conventional forged driver heads have a welding line on the face (inside the head) making the thinner part of the face smaller than you can see from outside the head. Integra’s drivers feature cup-face construction, making the areas of the clubface perimeter thinner and creating more face deflection for higher ball speeds to areas other than the center of the face. The face plate is bent at the perimeter, i.e. bending over the leading edge and allowing for a welding line at the clubhead’s body instead of welding at the actual face. Integra Golf’s cup-face technology provides you that extra spring-like effect for longer shots at a fraction of the cost of a cast titanium driver head.

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