InterBolt: Revolutionising Bolt Monitoring

InterBolt is on a mission to develop disruptive technologies that transform the way the world monitors its most critical assets. Last year, they had support from Suffolk Economy Grants and the North Star Business Support programme, helping them to embark on the next phase of their expansion.

We caught up with founder and CTO, Jack Hughleigh, to learn more.

What does InterBolt do, and what makes it innovative?

Founder and CTO Jack Hughleigh

InterBolt has developed a miniature, high-accuracy bolt load sensor that can be embedded directly into a bolt or stud. This allows bolt load to be measured on-site and remotely, enabling predictive maintenance and preventing failures before they happen.

It’s the first product of its kind on the market, and we have been rolling out the technology for about 2.5 years now.

What is the story behind InterBolt?

The idea came to me six years ago while on sabbatical along the Kenyan coast. A wheel nut came loose on our truck on Christmas Eve, while travelling through a remote area. This left us stranded and could have caused an accident, but it also sparked the idea for a sensor that could detect bolt failure before it occurs. InterBolt was born from that moment.

What are the practical applications?

Our technology is applicable wherever bolt performance is critical, particularly to improve safety and reliability. During our first 18 months we were focused on the oil and gas sector, before diversifying into the wind and mining industries. 

InterBolt has also been widely deployed in the rail industry where high vibration leads to bolt loosening. Over the last year, the technology has been installed on the New York Transit system, London Underground as well as mainline in the UK, Spain and France.

Tell us more about your base here in Suffolk

InterBolt is based in Bury St Edmunds, where we’ve established our manufacturing facility and are continuing to grow our team, with a strong focus on employing local people. Suffolk has become an important base for us as our work in clean energy has grown.

Offshore wind is a major local industry, and that is one of the primary applications we’re currently seeing for InterBolt. In the wind sector, bolt inspection is one of the most expensive and high-risk maintenance activities, accounting for around 30% of annual maintenance costs, while still often failing to prevent serious faults.

Our aim is to reduce the need for manual inspection, which reduces maintenance costs, minimises downtime, and significantly lowers health and safety risks for technicians working at height.

What support did you receive from Suffolk Economy

InterBolt initially received guidance and support from Innovate UK, before coming to Suffolk Economy for local support. We met with High Growth Advisor Robert Turnbull, who was really knowledgeable about the help we could access.

Robert came and looked around our facility in order to advise us on the best next steps. We have now taken on a new manufacturing facility which quadruples our footprint and have expanded our machining capabilities with a new CNC lathe.

Looking ahead

With a growing team in Suffolk and cutting-edge technology already proving its impact across multiple sectors, InterBolt is focused on scaling production, expanding into new markets, and continuing to innovate.

We want to support ambitious and disruptive businesses across the county. Learn more about Suffolk Economy Grants, and about the business support provided through schemes like North Star.