Structural Support Optimization System for Diverse Applications

Publication ID: 24-11857851_0002_PTD

Published: October 28, 2025

Category:New Applications & Use Cases

Legal Citation

pr1or.art Inc., “Structural Support Optimization System for Diverse Applications,” Published Technical Disclosure No. 24-11857851_0002_PTD, Published October 28, 2025, available at https://archive.pr1or.art/24-11857851_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. 11,857,851.

Summary of the Inventive Concept

This inventive concept applies the core technology of optimized structural support to various industries beyond golf club heads, enabling innovative solutions for wind turbine blades, prosthetic limbs, spacecraft, medical implants, and building foundations.

Background and Problem Solved

Traditional design and manufacturing approaches in various industries often result in suboptimal structural support, leading to reduced performance, increased weight, and compromised safety. The original patent introduced a novel method for creating optimized support structures in golf club heads. However, its application was limited to the golf industry. This inventive concept addresses the need for adaptable, high-performance structural support solutions across diverse industries.

Detailed Description of the Inventive Concept

The inventive concept leverages the original patent's binder jetting and sintering techniques to create optimized support structures with continuously changing curvature, rate of change of curvature, and cross-sectional area. These structures can be tailored to specific industries and applications, such as wind turbine blades, prosthetic limbs, spacecraft, medical implants, and building foundations. The system comprises interconnected nodes connected by slender elements with optimized curvature, enabling the distribution of stress and optimization of load-bearing capacity.

Novelty and Inventive Step

The inventive concept's novelty lies in its application of the original patent's technology to entirely new industries, solving specific problems and limitations inherent in each field. The inventive step is the recognition of the broader applicability of optimized structural support and the development of tailored solutions for diverse industries.

Alternative Embodiments and Variations

Alternative embodiments may include the use of different powdered materials, binder jetting machines, or sintering processes. Variations could involve adapting the system for use in other industries, such as aerospace, automotive, or energy, or integrating the technology with other manufacturing techniques, like 3D printing or machining.

Potential Commercial Applications and Market

The inventive concept has significant commercial potential in various industries, including renewable energy, healthcare, aerospace, and construction. By providing optimized structural support solutions, this technology can enable the creation of more efficient, durable, and cost-effective products, leading to increased market share and revenue growth.

CPC Classifications

Section	Class	Group
A	A63	A63B53/0487
A	A63	A63B53/0408
B	B22	B22F10/14
B	B22	B22F10/80
B	B33	B33Y10/00
A	A63	A63B53/0412

Section 103 Obviousness Analysis (PHOSITA)

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Field of Art

Advanced Manufacturing and Structural Design, focusing on additive manufacturing techniques like binder jetting, powder metallurgy, and complex geometric design for structural components across multiple engineering domains

Person of Ordinary Skill (PHOSITA) Profile

A skilled engineer with expertise in advanced manufacturing techniques, materials science, CAD modeling, and structural optimization, capable of translating design principles across different technical domains

Obviousness Rationale

A PHOSITA would recognize that the core manufacturing technique of binder jetting and sintering powdered materials to create complex support structures with continuously changing geometries is directly transferable across multiple technical domains. The fundamental principles of stress distribution, load optimization, and geometric design demonstrated in the golf club head support structure can be systematically adapted to other structural applications by applying known engineering design principles. The PTD represents a predictable extension of the source patent's core technological approach.

Obvious Combinations & Variations

Source Patent Element

Binder jetting method for creating golf club head support structures with continuously changing cross-sectional shapes

PTD Variation

Applying identical binder jetting technique to create support structures for wind turbine blades

Obviousness Reasoning

Known manufacturing technique applied to a structurally analogous domain with predictable optimization results

Source Patent Element

Support members extending at an angle from a sole portion with no sharp corners

PTD Variation

Creating interconnected support nodes for spacecraft structural components using similar geometric principles

Obviousness Reasoning

Transferring stress distribution design principles across engineering domains using well-established design optimization techniques

Source Patent Element

Sintering powdered materials to create complex geometric support structures

PTD Variation

Developing medical implant support structures mimicking bone geometry using identical manufacturing process

Obviousness Reasoning

Predictable application of established manufacturing method to biomimetic design with known material science principles

Source Patent Element

Curved spline support members with length at least three times equivalent diameter

PTD Variation

Creating prosthetic limb support networks with continuously changing curvature and cross-sectional area

Obviousness Reasoning

Systematic translation of structural design principles using known geometric optimization techniques

Source Patent Element

Complex geometric support structure manufacturing via binder jetting

PTD Variation

Developing building foundation support systems with interconnected nodes and stress distribution

Obviousness Reasoning

Applying established structural design methodology to civil engineering domain using predictable design transfer

35 U.S.C. § 103 Summary: Based on US Patent 11857851's disclosure of binder jetting manufacturing techniques for creating complex support structures with continuously changing geometries, the present publication demonstrates that a person having ordinary skill in the art would find the disclosed variations in wind turbine, spacecraft, medical, and architectural domains to be obvious extensions of the source patent's core technological approach, thereby rendering potential claims in these domains anticipated or obvious under 35 U.S.C. § 103.

Original Patent Information

Patent Number	US 11,857,851
Title	Support structures for golf club heads and methods of manufacturing improved support structures
Assignee(s)	Topgolf Callaway Brands Corp.