Additive Manufacturing for Customized Solutions

Publication ID: 24-11857848_0002_PTD

Published: October 28, 2025

Category:New Applications & Use Cases

Legal Citation

pr1or.art Inc., “Additive Manufacturing for Customized Solutions,” Published Technical Disclosure No. 24-11857848_0002_PTD, Published October 28, 2025, available at https://archive.pr1or.art/24-11857848_0002_PTD

This technical disclosure describes improvements that would be readily apparent to a Person Having Ordinary Skill In The Art (PHOSITA) when considered in combination with the foundational architecture disclosed in U.S. Patent No. 11,857,848.

Summary of the Inventive Concept

Applying the core technology of additive manufacturing for golf club heads to create customized solutions in various industries, including prosthetics, orthotics, bicycles, hearing aids, and exoskeletons.

Background and Problem Solved

The original patent disclosed the use of additive manufacturing for golf club heads, but its limitations were confined to the golf industry. The new inventive concept addresses the need for customized solutions in various fields, leveraging the benefits of additive manufacturing to create complex geometries, reduce weight, and improve performance.

Detailed Description of the Inventive Concept

The new inventive concept comprises a computer-aided design module, a 3D printing module, and a lattice structure formation process. The design module receives user input or scans to generate a customized 3D model, which is then fabricated by the 3D printing module using an additive manufacturing process. The lattice structure is designed to provide customized support, cushioning, or stiffness, depending on the application. In prosthetics, the lattice structure enables customized fit and comfort. In orthotics, it provides support and cushioning for the patient's foot. In bicycles, it reduces weight while maintaining stiffness. In hearing aids, it improves sound quality and comfort. In exoskeletons, it offers customized support and stability.

Novelty and Inventive Step

The new claims introduce a novel application of additive manufacturing to various industries, leveraging the benefits of lattice structures to create customized solutions. The inventive step lies in the adaptation of the original patent's technology to address specific problems in these new fields, resulting in a non-obvious and innovative solution.

Alternative Embodiments and Variations

Alternative embodiments may include the use of different additive manufacturing techniques, such as selective laser sintering or stereolithography. Variations may include the integration of sensors or actuators to enhance the functionality of the customized solutions.

Potential Commercial Applications and Market

The new inventive concept has significant commercial potential in various industries, including healthcare, sports, and consumer electronics. The market demand for customized solutions is increasing, driven by the need for personalized products that cater to individual needs and preferences.

CPC Classifications

Section	Class	Group
A	A63	A63B53/04
B	B23	B23K26/342
B	B33	B33Y40/20
B	B33	B33Y80/00
A	A63	A63B53/047
A	A63	A63B53/0412
A	A63	A63B53/0466
A	A63	A63B53/0487
A	A63	A63B53/08
A	A63	A63B2053/0491
A	A63	A63B2209/00
B	B22	B22F10/00

Section 103 Obviousness Analysis (PHOSITA)

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Field of Art

Additive Manufacturing and Sports Equipment Design, specifically focusing on 3D printing techniques for complex structural components in golf clubs and biomechanical devices

Person of Ordinary Skill (PHOSITA) Profile

A skilled practitioner with expertise in advanced manufacturing techniques, computer-aided design, materials engineering, and biomechanical design, possessing knowledge of 3D printing processes, lattice structure optimization, and customized component fabrication

Obviousness Rationale

A PHOSITA would recognize that the core additive manufacturing principles demonstrated in the golf club patent can be readily extended to other biomechanical and sports-related applications by applying known 3D printing techniques and lattice structure design principles. The fundamental technological approach of using computer-aided design, precise 3D printing, and customizable lattice structures represents a transferable methodology across multiple technical domains. The variations disclosed in the PTD represent predictable adaptations of existing additive manufacturing technologies to solve domain-specific design challenges.

Obvious Combinations & Variations

Source Patent Element

Additive manufacturing process for creating a golf club head with internal lattice structure

PTD Variation

Applying identical additive manufacturing process to create prosthetic limbs with customized internal lattice structures

Obviousness Reasoning

Known 3D printing techniques can be predictably applied across biomechanical domains, with lattice structure optimization being a standard design approach for weight reduction and structural performance

Source Patent Element

Computer-aided design module for generating golf club head geometry

PTD Variation

Extending design module to generate customized hearing aid and orthotic geometries

Obviousness Reasoning

Parametric design techniques are universally applicable across domains requiring precise, customized geometric modeling

Source Patent Element

Weight placement and structural optimization in golf club head

PTD Variation

Implementing similar weight distribution and structural optimization principles in bicycle frame design

Obviousness Reasoning

Performance optimization through strategic material placement is a standard engineering approach across mechanical design domains

Source Patent Element

Internal cavity and lattice structure in golf club head

PTD Variation

Creating customized support structures in exoskeletons using similar lattice design principles

Obviousness Reasoning

Lattice structures provide predictable mechanical properties that can be systematically designed for different load-bearing applications

Source Patent Element

Additive manufacturing technique for complex geometrical components

PTD Variation

Applying identical manufacturing process to create patient-specific medical devices with intricate internal structures

Obviousness Reasoning

3D printing enables complex geometries across multiple domains, with material selection and printing parameters being systematically adaptable

35 U.S.C. § 103 Summary: Pursuant to 35 U.S.C. § 103, the technical variations disclosed herein would have been obvious to a person having ordinary skill in the art at the time of invention, as demonstrated by the substantial technological overlap between US Patent 11857848 and the present published technical disclosure. The fundamental additive manufacturing methodology, including computer-aided design, lattice structure optimization, and precision 3D printing techniques, represents a predictable technological approach readily adaptable across multiple technical domains without requiring inventive insight beyond the capabilities of an ordinary skilled practitioner.

Original Patent Information

Patent Number	US 11,857,848
Title	Systems and methods for additive manufacturing of a golf club
Assignee(s)	Cobra Golf Incorporated