Ultrasonic-based measurement systems for determining preload in high-strength bolted connections.
Intellifast GmbH
SpeyerNew on Amplifa
About Intellifast
Intellifast GmbH, headquartered in Speyer, develops, manufactures and distributes ultrasonic-based measurement systems for determining preload in high-strength bolted connections. The intellifast® system comprises permanently mounted, plasma-coated ultrasonic transducers (Intelli.bolt®), fourth-generation measuring devices (LoadProbe 4xx) and the LoadView software. The technology traces back to ultrasonic preload measurement for the Sojourner Rover of NASA's Mars Pathfinder mission. In addition to measuring clamp loads, verifying bolted joints and alternative methods such as strain gauges, the company offers in-house development, design, production and assembly of the systems as well as services such as training, calibration, documentation, on-site measurement and repairs. Customers come from aerospace, energy (including offshore wind), mechanical and structural engineering, automotive research and the fastener industry. Since 2023, Intellifast has been part of the family-owned ITH Group; the QM system is certified to EN 9100:2018 and DIN EN ISO 9001:2015.
- Site
- Speyer
- Processes
- Ultrasonic preload measurement in bolted joints (intellifast® system, plasma transducers), Verification of bolted joints, Design, manufacturing and assembly of preload measurement equipment, In-house development of ultrasonic measurement systems & software, Production of Intelli.bolt® plasma transducers (permanent-mounted plasma coated transducers), Customer services: training, calibration, documentation, on-site measurement, repairs, 100% testing of transducers before shipment, Preload measurement with strain gauges
- Materials
- Permanent Mounted Transducer Systems, Data Acquisition Unit (ultrasonic card), LoadProbe measuring devices (410/416/450), LoadView Software, Strain gauge method, Length measurement method
- Certificates
- EN 9100:2018 (based on ISO 9001:2015), DIN EN ISO 9001:2015, TÜV SÜD CE conformity (measuring devices), Germanischer Lloyd wind product certificate (plasma transducer), EN 9100:2018, DIN EN 4859:2017, TÜV SÜD CE conformity, Germanischer Lloyd Wind, PPAP (QS 9000), 100% testing of transducers
- Founded
- 1996
- Industries
- Aerospace, Energy (e.g. offshore wind), Mechanical engineering / structural steel construction, Automotive (R&D), Fastener industry
- 01
In-house development (measurement systems & software)
- 02
Design
- 03
Production of plasma transducers
- 04
Assembly
- 05
100% testing of transducers before shipment
- 06
Distribution
- 07
Service (training, calibration, documentation, on-site measurement, repairs)
Technology & Processes
Permanent Mounted Transducer Systems
Permanently mounted, plasma-coated ultrasonic transducers for preload measurement in high-strength bolts.
Data Acquisition Unit (ultrasonic card)
Data acquisition card for ultrasonic measurements, in use since 2011.
LoadProbe measuring devices (410/416/450)
4th-generation ultrasonic measuring devices for single- and multi-channel measurements, some ruggedized (LoadProbe 416).
LoadView Software
Software for evaluation and monitoring of measurement data from the LoadProbe family.
Strain gauge method
Precise but elaborate alternative method for preload measurement on bolts.
Length measurement method
Cost-effective preload determination via elongation using mechanical or optical tools, with limited accuracy.
Locations
Speyer
DEHeadquarters: development, production, sales
- LoadProbe 416
- LoadProbe 410
- LoadProbe 450
- LP Touch V1/V2
- LP3000 B/E
- LP2000
- DAU ultrasonic card
Products & Systems
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Ultrasonic preload measurement in bolted joints (intellifast® system, plasma transducers)Testing | – | – | – | – | high tensile bolts |
| Verification of bolted jointsTesting | – | – | – | – | high tensile bolts |
| Design, manufacturing and assembly of preload measurement equipmentAssembly | – | – | – | – | – |
| In-house development of ultrasonic measurement systems & softwareEngineering | – | – | – | – | – |
| Production of Intelli.bolt® plasma transducers (permanent-mounted plasma coated transducers)Surface treatment | – | – | – | – | – |
| Customer services: training, calibration, documentation, on-site measurement, repairsTesting | – | – | – | – | – |
| 100% testing of transducers before shipmentTesting | – | – | – | – | – |
| Preload measurement with strain gaugesTesting | – | – | – | – | bolts |
| Preload measurement via elongation (mechanical or optical tools)Testing | – | – | – | – | bolts |
9 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Ultrasonic measurement device (LoadProbe 416, one-channel) | Intellifast LoadProbe 416 | – | – | 2025 | Speyer |
| Ultrasonic measurement device | Intellifast LoadProbe 410 | – | – | 2018 | – |
| Ultrasonic measurement device (Preload Monitoring System) | Intellifast LoadProbe 450 | – | – | 2018 | – |
| Ultrasonic measurement device | Intellifast LP Touch V2 | – | – | 2013 | – |
| Ultrasonic measurement device | Intellifast LP Touch V1 | – | – | 2011 | – |
| Ultrasonic measurement device | Intellifast LP3000 B | – | – | 2006 | – |
| Compact digital ultrasonic measurement device | Intellifast LP3000 E | – | – | 2004 | – |
| Compact analog ultrasonic measurement device | Intellifast LP2000 | – | – | 2002 | – |
| Data Acquisition Unit (DAU) ultrasonic card | Intellifast DAU | – | – | 2011 | – |
Additional services
Quality & Certification
Every transducer is 100% tested before shipment. Manufacturing is certified to DIN EN 9100:2018 (since 2006, annual audits) and DIN EN ISO 9001:2015; further evidence includes DIN EN 4859:2017, TÜV-CE conformity of the measuring devices, the Germanischer Lloyd wind product certificate and PPAP per QS 9000.
| Evidence | Speyer |
|---|---|
| EN 9100:2018 | |
| DIN EN ISO 9001:2015 | |
| DIN EN 4859:2017 | |
| TÜV SÜD CE conformity | |
| Germanischer Lloyd Wind | |
| PPAP (QS 9000) | |
| 100% testing of transducers |
Company History
- Anfang der
Development of the ultrasonic preload measurement technology for the Sojourner Rover (NASA Mars Pathfinder)
- 1993
NASA award for the “Smart Bolts” program, won by ULTRAFAST
- 1996
Founded as ULTRACOAT in Germany
- 1998
Production of plasma transducers starts in Eisenach
- 2001
Safeguard Int. acquires the assets of ULTRAFAST and ULTRACOAT; relocation to Speyer
- 2002
100% subsidiary of PFW; renamed PFW Technology GmbH; first compact analog measuring device LP2000
- 2003
Renamed Intellifast GmbH
- 2004
First compact digital measuring device LP3000 E
- 2006
Launch of LP3000 B; EN 9100 certification
- 2011
Introduction of the DAU ultrasonic card; launch of LP Touch V1
- 2013
Launch of LP Touch V2
- 2016
Acquisition by Aero Products Invest, Augsburg
- 2018
Launch of LoadProbe 4xx / LoadView (4th generation); first PMS installation in an offshore wind farm
- 2023
Joined the family-owned ITH Group
- 2025
Launch of the rugged LoadProbe 416; Dr.-Ing. Rodolphe Catrin becomes CEO (May)