Competition Kettlebell Made from Pressed Steel Halves

The problem

Kettlebells are simple objects with an awkward way of being made. Cast iron bells need a sand mold for each pour, and the finish, wall thickness and final weight vary from bell to bell. Competition kettlebells - used in kettlebell sport (girevoy sport) - add another demand: every weight is expected to have the same outer size and handle, so the lifter’s technique does not change as the weight goes up. Cast-steel competition bells meet that, but they are expensive. The patent proposes making the bell from pressed sheet steel instead.

The solution

The patent builds the kettlebell from formed and welded parts:

1. The body is a spherical shell (2) made of an upper half (20) and a lower half (21), each deep-drawn from steel plate on a hydraulic press.
2. The upper half is punched with two oval holes (200), and the two halves are welded together at the seam.
3. The shell is filled through the holes with a mass (3) that brings the bell to its weight - the patent lists materials such as sand, iron ore, steel balls and shot.
4. A U-shaped handle (1), bent from steel bar, is pushed into the holes and welded to the shell, closing them.
5. The bottom is pressed flat so the bell stands steady; the front and back have flat faces for the logo and weight.
6. The shell gets a paint layer (4) that extends onto the handle, and the handle is electroplated (5).

Who it is for

• Fitness equipment brands that want competition-style bells at a lower cost than cast steel.
• Gym and CrossFit-style box suppliers buying full sets where every bell must look and feel the same.
• E-commerce fitness sellers looking for a cleaner, more uniform finish than budget cast iron.
• Kettlebell sport clubs and coaches ordering branded bells for training groups.

How it works

The main parts

How the bell is made

The patent lists the steps:

1. Handle - draw steel bar, cut, bend into a U, shape, grind, polish and plate.
2. Blanking - cut steel plate into blanks for the two halves.
3. Deep drawing - press each blank into a hemisphere in a drawing die on a four-column hydraulic press.
4. Trimming - grind, deburr and trim the edges.
5. Punching - punch the two oval handle holes in the upper half.
6. Flattening - press the bottom of the lower half flat.
7. Welding - size both halves, fit them together, weld the seam and grind it smooth.
8. Filling - fill the shell to the nominal weight through the handle holes.
9. Handle - insert the handle ends into the holes, weld them and grind the welds flat.
10. Finishing - inspect and true the surface, then paint with the handle grip masked.

Applications

Commercial gyms

Matched sets where every weight shares one shell size, ordered in gym colors with the club logo.

Kettlebell sport training

Competition-style dimensions so lifters keep the same technique from light to heavy bells.

Home gyms

A smooth, uniform finish that is kinder to floors and easier to clean than rough cast iron.

Corporate wellness and hotel gyms

Branded bells with flat logo faces for printing.

Physical-training programs

Uniform bells for schools, teams and fitness classes.

Where it is less suitable

• Very heavy bells outdoors without care - a welded, filled shell must be sealed well so moisture cannot get inside.
• Buyers who require official competition approval - federation-approved bells follow exact specifications that must be confirmed separately.