David James and Ross Miller, founders of James Miller Solutions, created the system after spending hundreds of hours designing and testing it at a Morriston workshop.

Lightning and high-voltage earthing conductors are installed anywhere a lightning strike could cause damage, power outages or safety risks. This includes public buildings, churches, stadiums, hospitals, industrial sites, airports, power stations and electrical substations.

Bonding copper or aluminium together forms part of the installation of these conductors, although traditional ways of doing this have included the use of blow torches. This carries risks including safety, process failure and high carbon emissions.

Recognising the challenges, David and Ross have now created an induction-based process that means the bonding of metals can be done more safely, more consistently and with far less risk – even though some industry experts said it couldn’t be done.

The idea came from their day-to-day work, where they realised that the way these systems are connected has barely changed in decades.

The pair first met while working as electricians for Swansea Council.

David now teaches renewable energy at Gower College Swansea, while Ross still works as an electrician for the council.

David said:

“We’ve both worked in the industry for many years, and coming from Swansea — with its strong copper and engineering history — we’ve always understood the importance of working safely and precisely with metals.

“What we’ve developed in our own time replaces traditional high-risk methods with induction-based joining, giving much greater control and significantly reducing risks during installation.

“The idea came during a live job in Port Talbot during Covid, when it became clear there had to be a better way. From there, we spent hundreds of hours developing and refining the system in a shed.”

Ross said:

“It involved constant testing and refining, even when we were told it wouldn’t work.

“In many ways, it reflects Swansea’s long engineering tradition — solving real problems through practical innovation.”

Independent testing at Cardiff University’s high voltage laboratory showed the system could handle electrical loads around three times stronger than a typical lightning strike.

Further testing was also carried out at Swansea University’s Swansea Materials Research and Testing (SMaRT) facility at the bay campus. This found it could withstand heavy physical force — up to 9,700 lbs — without failing.

The project was supported by a Swansea Council business innovation grant, funded through the UK Government’s Shared Prosperity Fund.

As well as improving safety, the new method also helps to reduce environmental impact by cutting out the need for methods that rely only on open flames or high heat chemical reactions.

David said:

“This isn’t just about safety — it’s also about sustainability. On large projects like substations and infrastructure, this approach could significantly reduce carbon emissions compared to traditional methods.”

The project has also changed the course of David and Ross’s careers.

Their work attracted support from the Royal Academy of Engineering, with James Miller Solutions selected for its Regional Talent Engines programme. This allowed Ross to work on the technology full-time, supported by Swansea Council through a secondment.

Ross said:

“We never set out to become entrepreneurs — we were just trying to solve a problem we faced at work. But along the way we’ve become inventors and business owners, which has been an incredible experience.

“The support we’ve had has helped us move faster, but at its core this is still about improving safety, reliability and sustainability in the industry.”

Cllr Rob Stewart, Swansea Council Leader, said:

“David and Ross are a fantastic example of the innovation, skills and ambition we have here in Swansea. It’s inspiring to see two people who started their careers with the council develop an idea that has the potential to improve safety and sustainability across the electrical industry.

“We’re delighted that our business innovation grant, funded through the UK Shared Prosperity Fund, has helped them take this technology from concept towards commercial reality.

“Supporting businesses like James Miller Solutions is part of our vision to create stronger, more resilient businesses that generate high-quality jobs, drive innovation and deliver long-term benefits for Swansea and its communities.”

David and Ross believe their technology could help set a new standard for how electrical connections are made — replacing older methods that can be risky, produce higher emissions and depend heavily on operator skill.

The innovation is already attracting interest from electricity network operators, major contractors, universities and industry bodies.

James Miller Solutions is currently in discussions with Distribution Network Operators (DNOs), the Energy Networks Association (ENA) and other organisations about trials and future use.

Looking ahead, David and Ross plan to expand the technology into infrastructure and construction projects across South Wales and beyond.

They are now seeking partners interested in working with them to bring the system into wider use. Businesses interested in learning more can contact James Miller Solutions on ross@jamesmillersolutions.co.uk or david@jamesmillersolutions.co.uk