Patent ID: 7862452

Claim:
A method of manufacturing a golf club head, comprising: forming a face insert to a thickness of about 4.5 mm or less, the face insert at least partially including prepreg plies having a fiber areal weight of less than 100 g/m 2 , wherein forming the face insert comprises debulking a stacked plurality of plies such that impurities are driven to the edges of the plies and cutting the stack of plies to a size substantially the same as a final desired size and not including the edges having the impurities; forming a body having a crown, a skirt and a sole, the body defining a front opening, the body having an annular ledge recessed a depth D in the front opening; attaching the face insert to the front opening, wherein the face insert has a thickness less than the depth D of the annular ledge in the front opening of the body; forming a metallic cap having a peripheral rim extending around the periphery of the face insert; and adhesively attaching the metallic cap to the face insert.