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Cooking smaller, individual-sized hamburgers with onions and bacon in a cast iron skillet on the grill can be a delicious and satisfying meal. To prevent them from falling apart, follow these steps:

1. Choose the Right Ground Beef: Use ground beef with a slightly higher fat content (around 80/20 or 85/15) to ensure the burgers stay moist and hold their shape better during cooking.

2. Properly Season the Burgers: Season the ground beef with salt, pepper, and any other desired seasonings. Be gentle when mixing the seasonings into the meat to avoid overworking it, which can lead to tougher burgers.

3. Make Evenly Sized Patties: Divide the seasoned ground beef into equal portions and shape them into patties of even thickness. Press the center of each patty slightly thinner than the edges to prevent them from puffing up in the middle while cooking.

4. Chill the Patties: After shaping the patties, place them in the refrigerator for about 15-20 minutes before cooking. Chilling the patties helps them hold their shape better during cooking.

5. Preheat the Cast Iron Skillet: Place the cast iron skillet on the grill and preheat it before adding the bacon and onions. This will help prevent the ingredients from sticking.

6. Cook the Bacon and Onions First: Cook the bacon in the preheated skillet until it's crispy. Remove the bacon and set it aside. Then, cook the onions in the bacon fat until they become soft and caramelized. Remove the onions and set them aside.

7. Cook the Burgers: Add a little oil or butter to the skillet if needed. Place the chilled burger patties into the hot skillet and cook them over medium-high heat. Avoid overcrowding the skillet to ensure even cooking.

8. Avoid Over-flipping: Let the burgers cook on one side until they develop a nice sear and are easily lifted from the skillet without sticking. Avoid pressing down on the burgers with the spatula, as it can squeeze out the juices and make them dry.

9. Add Bacon and Onions Back: When the burgers are almost cooked to your desired level of doneness, add the cooked bacon and caramelized onions on top of each patty in the skillet.

10. Add Cheese (Optional): If you prefer cheese on your burgers, place a slice of cheese on top of each patty and let it melt over the bacon and onions.

11. Serve: Once the burgers are cooked to your liking and the cheese has melted (if using), remove the skillet from the grill and serve the individual-sized burgers on buns or as desired.

By following these steps, you can cook smaller hamburgers with onions and bacon in a cast iron skillet on the grill without them falling apart. The cast iron skillet will help enhance the flavors and create a delicious meal for you and your guests to enjoy.

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