The Modular Wedge

The project originated by addressing rapid wedge groove degradation and the recurring financial burden of full-club replacements. Early ideation focused on creating a wedge with a replaceable clubface, upholding spin rates at a fraction of the cost. Referencing the tour-validated profile of the Cleveland RTX ZipCore to maintain traditional blade proportions and address acoustics.

Transitioning sketches into 3D CAD required balancing strict playing constraints with internal mechanical packaging. Critical playing parameters—loft angle, lie angle, and insert pocket clearances—were rigidly defined, while surrounding muscle-back contours and top-line radii were sculpted to seamlessly house the mechanical locking hardware.

Before committing to high-cost subtractive metal fabrication, a full-scale 3D print served as an essential verification gate. This physical audit tested seam-line flushness, fastener pocket depths, and overall ergonomics in the hands, preventing costly tooling mistakes and validating assembly clearances prior to machine shop programming.

Production advanced to a two-week precision CNC subtractive milling cycle across all primary metallic components. In-process toolpath modifications were made to account for physical cutter geometry, including adding internal corner relief radii to ensure clean end-mill clearing and tour-grade mechanical seating across all inserts

Post-machining trials compared brush polishing against abrasive media sandblasting, with sandblasting chosen for its superior, glare-reducing matte consistency. Sealed with a protective micro-wax treatment to resist oxidation and fingerprint marks, the resolved platform delivers complete turf adaptability and instant groove refreshes in a shelf-ready design.