Kettlebell from Apus Sports was designed with functional training improvement on our mind.

The first step was an ergonomic analysis of the way people grab kettlebell during their training. Observation and interviews with personal trainers, fitness club attendees, and competitor analysis was the best ground to start working at the first concepts.

Next step was modeling the weights, testing grip ergonomics and the shape of the kettlebell. Proportional scaling found out to be a great challenge.

Each Kettle is different and has a different shape. Each weight has been designed to feature a comfortable handle and make Kettle easily and safely operable. The Kettles have not been scaled in any way, only each one of the weights has been designed individually.

The biggest problem we faced with the Kettle, was that we had to begin with lower weight, i.e. 4kg, when designing it. With a small Kettle, we had to make the head considerably heavy, but we couldn’t do the same with the handle. It had to be practical for exercises and comfortable for pulling. The challenge we faced was compromising the optimum diameter of the handle (grip) and keep the correct weight of the Kettle. By taking mass from the Kettle’s head and creating a handle of a greater diameter, we would receive a more ergonomic handle. But the head weight had to be bigger to facilitate in doing exercises correctly. It enabled us to properly use the laws of physics influencing the Kettle.

If we want to effectively swing an object, the center of gravity must be situated quite far forward. This Kettle from Apus Sports is constructed in such a way. Additionally, owing to its droplet shape, its bottom is more flattened and its base is more stable. This makes it suitable, among others, for doing push-ups.

First prototypes with target materials and technology were the test to compare the shape, ergonomics and manufacture techniques with our ideas devised in SolidWorks. It found out that the Kettlebell was too thick covered with a vinyl coating. Material flooded all ergonomic shapes of the Kettlebell. We had to calculate those differences and prepare the 3D model the way it includes the thickness of the material.

The final project is the set of seven Kettlebells made of cast iron, covered in anti-slippery and resistant do mechanical damages vinyl coating. It is the basic equipment for every gym and fitness club.