A method for producing a golf club head (42) with a face component (60) and an aft-body (61) is disclosed herein. The face component (60), which includes a striking face (72) having a variable face thickness and a return portion is formed from a custom sheet or strip (50) of metal material that has been formed to have a desired thickness profile, with at least one portion of the sheet having a greater thickness than another section. A blank pattern of the face component (51) is cut from the sheet of metal material and formed into the face component (60). The face component (60) is then welded and attached to the aft-body (61).