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Threaded fasteners appear to be the best low cost option for applying a desired clamp load to assemble a joint, which can be disassembled, if necessary, at a low cost. A large number of joint failures are due to inadequate tension on the joint. Most conventional tightening methods only provide a vague indication of the bolt tension. In this paper we will discuss the development of the A‐BOLT™ system, which can measure the tension in the mechanical bolt to ±1 per cent accuracy of the proof load. The key element of the system is a specially designed mechanical bolt with a top‐mounted sensor to measure the bolt elongation. We will also describe the development of different generations of the A‐BOLT™ system and its industrial applications. Finally we will present an overview of research on the cluster based networking of wireless sensors to minimize energy consumption in a network of sensors.