Forming the center
•1 The center of the two-piece ball is a molded core. It is a blend of several different ingredients, all of which are chemically reactive to give a rubber type compound. After heat and pressure is applied, a core of about 1.5 inches (3.75 cm) is formed.
Forming the cover and dimples
•2 Injection molding or compression molding is used to form the cover and dimples on a two-piece ball using a two-piece mold. In injection molding, the core is centered within a mold cavity by pins, and molten thermoplastic is injected into the dimpled cavity surrounding the core. Heat and pressure cause the cover material to flow to join with the center forming the dimpled shape and size of the finished ball. As the plastic cools and hardens, the pins are retracted and the finished balls are removed.
•3 With compression molding, the cover is first injection molded into two hollow hemispheres. These are positioned around the core, heated and then pressed together, using a mold which fuses the cover to the core and also forms the dimples. Three-piece balls are all compression molded since the hot plastic flowing through would distort and probably cause breaks in the rubber threads.
Polishing, painting, and final coating
•4 "Flash" or rough spots and the seam on the molded cover are removed. Two coats of paint are applied to the ball. Each ball sits on two posts, which spins so that the paint is applied uniformly. Spray guns that are automatically controlled are used to apply the paint. Next, the ball is stamped with the logo. The final step is the application of a clear coat for high sheen and scuff resistance.
Drying and packaging
•5 After the paint is applied, the balls are loaded into containers and placed in large dryers. After drying, the balls are ready for packaging in boxes and other containers.