BRIGHTFUSER FUSER500 Assembly instructions
OWNER’S MANUAL & SAFETY INSTRUCTIONS
VERSION 4
SAVE THIS MANUAL
Keep this manual for safety warnings, precautions, operating, and cleaning procedures. Keep this manual and
proof of purchase for future reference.
When unpacking, make sure that the product is intact and undamaged. If any parts are missing or broken,
please visit www.brightfuser.com to contact us.
WARNING
Read this material before using this product. Failure to do so may result in product damage and severe injury.
1. Introduction_____________________________________________________________________ 03
2. Fuser500™ parts list ______________________________________________________________ 04
3. Safety, maintenance, and storage____________________________________________________ 05
4. Timeline overview ________________________________________________________________ 06
5. Fuser500™ lost-wax casting process ________________________________________________ 07
• Selection of jewelry pattern ______________________________________________________ 07
• Connect the Fuser500™ vacuum pump to the mixer ___________________________________ 07
• Silicone mold preparation using the Fuser500™ mixer and vacuum pump __________________ 08
• Silicone mold wax injection using the Fuser500™ wax injector ___________________________ 12
• Wax injection techniques using the Fuser500™ wax injector ____________________________ 13
• Sprue confection and tree assembly ________________________________________________ 14
• Flask preparation using the Fuser500™ mixer and vacuum pump ________________________ 16
• Flask burnout using the Fuser500™ kiln _____________________________________________ 20
• Metal melting and pouring using the Fuser500™ casting base and vacuum pump ___________ 21
• Enjoy finishing and polishing your jewelry casting _____________________________________ 23
• BONUS: Stone setting using the Fuser500™ vacuum pump _____________________________ 24
Copyright 2022 by BrightFuser® LLC. All rights reserved. No portion of this manual or any artwork contained herein may be
reproduced in any shape or form without the express consent of BrightFuser. Diagrams within this manual may not be drawn
proportionally. The actual product illustrations may dier slightly from the product described herein.
TABLE OF CONTENTS
INTRODUCTION
Lost-wax casting is an intricate art dating back thousands of years. Despite being an ancient technique,
it has been undergoing significant transformation, perfected each and every day. Today, lost-wax casting
is one of the most reliable and eective methods used by jewelers worldwide.
The use of lost-wax casting gives jewelers the ability to adequalely produce similar pieces of jewelry in
large quantities at a relatively low cost.
Our Fuser500™ was developed by a father, an exceptional jeweler himself, committed to helping his
daughter reach her full potential as an artist, following his very own craft. Together, they conceptualized
the process you are about to experience.
Please make sure to read this material thoroughly before using the Fuser500™.
Visit www.brightfuser.com and follow us on social media to learn more.
Enjoy the experience!
3
• Clean Cloth
• Empty Water Container (large enough
to fit the flasks)
• Grease (used in bikes or boats)
• Low Power Soldering Iron, Pyrograph
or Wax Pen Tool
• Motor Oil
• Paper Towels
• Personal Protection Equipment
• Precision Scale
• Ruler
• Silica Crucible
• Small Screwdriver
• Super Glue
• Torch
• Water
PARTS LIST
The manufacturer and/or the distributor has provided the parts list and assembly diagram in this manual as a reference tool only.
The manufacturer and/or the distributor are not responsible nor liable for any repairs made by the buyer. The manufacturer and/or
the distributor expressly state that only a qualified technician should undertake all repairs or parts replacements. The buyer assumes
all risk and liability if any repairs or parts replacements are made by a non-qualified technician.
Additional items needed (not included):
Included items/parts:
• 1 Mixer
› 1 Mixing Chamber
› 1 Vacuum Chamber
› 1 Polycarbonate Lid
› 1 Mixing Glass
› 1 Power Cord
› 1 Flask Base
› 1 Flask Top
› 1 Rubber Filling Funnel
› 500 Grams of Investment Powder
• 1 Kiln
› 1 Large Flask
› 1 Medium Flask
› 1 Small Flask
› 1 Crucible Tongs
• 1 Casting Base
› 1 Casting Base Bottom
› 1 Casting Base Top
› 5 Paper Gaskets
• 1 Vacuum Pump
› 1 Vacuum Hose With Filter
› 1 Power Cord
› 1 End Cap
• 1 Wax Injector
› 1 Pressure Pump
› 100 Grams of Wax Inside
the Heating Reservoir
› 1 Power Cord
› 1 Vacuum Pen + 2 Suction Needles
› 1 Suction Silicone Tube (18 inches)
› 1 Sprue Silicone Tube (4 inches)
› 2 Pink Vacuum Suction Needles
• 1 Accessory Kit
› 1 Plastic Storage Box
› 1 Large Impeller
› 1 Small Impeller
› 1 By-pass Silicone Tube (10 inches)
› 2 Threaded Rods + 2 Nuts
› 1 Precision Knife
› 1 Lecron Carver
› 1 Allen Key
› 6 Molding Panels
› 4 Rubber Bands
› 3 Aluminum U-shaped Mold Frames
(Small, Medium, Large) + 3 Sprue Formers
› 1 Pink Wax Sheet
› 1 Silicone Mold Cutting Aid
› 1 End Cap
› Silicone Molding Rubber Compound
SAFETY, MAINTENANCE,
AND STORAGE
5
WARNING: Read all instructions before using this equipment.
When using any electrical equipment, basic precautions should always be followed, including the following
to reduce the risk of, but not limited to, fire, electric shock, or injury:
1. Operate the equipment only as described in this manual.
2. Do not leave equipment unattended when plugged in a power outlet. Unplug from the outlet when
not in use and before cleaning.
3. Do not use the equipment on wet surfaces. Do not expose to rain. Store indoors.
4. Stay alert and use common sense when operating the equipment. Do not use the equipment if tired
or under the influence of drugs, alcohol, or medication. A moment of distraction while operating the
equipment may result in personal injury and to others.
5. Do not allow children and/or an unqualified person to use the equipment. Keep children and pets
away during use. The equipment is not a toy.
6. Do not use if power cord or plug is damaged in anyway. Do not pull or carry the equipment by the
power cord. Keep power cords away from heated surfaces.
7. Do not unplug the equipment from the power outlet by pulling on the power cord. To unplug, grasp
the plug, not the power cord.
8. Turn o all necessary controls before unplugging.
9. Do not handle plug or equipment with wet hands.
10. To reduce your exposure to chemical reactions, vapors and other harmful products, always work in a
well-ventilated area.
11. Wear long pants, long sleeves, and protective footwear.
12. Wear Personal Protective Equipment. Wear ANSI-approved safety goggles. As appropriate, wear a
protective mask and gloves.
13. Maintain labels and nameplates on the product. These may carry important safety information. If
unreadable or missing, visit www.brightfuser.com to contact us.
14. The warnings, precautions, and instructions discussed in this owner manual cannot cover all possible
conditions and situations that may occur. It must be understood by the operator that common sense
and caution are factors that cannot be built into this equipment. Use your own caution.
15. If the equipment is not working, visit www.brightfuser.com to contact us.
TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION: Turn the power switch of the equipment
o and unplug the equipment from the electrical outlet before performing any procedure in this section.
TO PREVENT SERIOUS INJURY FROM EQUIPMENT FAILURE: Do not use damaged equipment. If abnormal
conditions occur, have the problem corrected before further use.
BEFORE EACH USE, inspect the general condition
of the equipment. Check for:
• Loose parts,
• Misalignment or binding issues,
• Cracked or broken parts,
• Damaged extension cords,
• Damaged electrical wiring, and
• Any other condition that may aect its safe operation.
AFTER EACH USE, clean parts as indicated.
• Store in an indoor dry area out of the
reach of children and pets.
• Failure to do so may result in
equipment damage and malfunction.
• Wipe external surfaces with a clean,
dry cloth.
6
TIMELINE OVERVIEW
1
4
7
2
5
8
3
6
Silicone mold preparation
Cure time: 2hrs
Tree assembly
Metal melting
Silicone mold cut
Investment powder/
flask preparation
Drying time: 2hrs
Jewelry ready for finishing
Silicone mold
wax injection
Kiln (flask
burnout)
3 ½and 4hrs
1. SELECTION OF JEWELRY PATTERN
2. CONNECT THE FUSER500™
VACUUM PUMP TO THE MIXER
7
At BrightFuser, we believe in compact tools by design. Our Fuser500™ takes casting to a whole new
level, allowing you to streamline your production.
To get started, select your jewelry pattern. Our equipment allows you to get creative and use models
made out of several materials, including metals, wood, plastic, resin, and even organic sources.
1. Connect the Fuser500™ mixer to a 110V outlet
2. You may connect the Fuser500™ vacuum pump plug into:
• Regular power outlet: Turn it on and o directly on the vacuum pump using the on/o switch.
• Mixer outlet (recommended): As long as the
Fuser500™ mixer is connected to a power outlet,
the vacuum pump can be left on and be turned
on/o using the vacuum switch on top of the mixer.
Fuser500™ Lost-Wax Casting Process
LET’S GET STARTED
3. SILICONE MOLD PREPARATION USING THE
FUSER500 MIXER AND VACUUM PUMP
8
EXPERT TIP: In this section, you will need a precision scale, a ruler, and super glue.
Custom silicone molds are reusable and can last for many years when properly cared for. They
are incredibly flexible, allowing for sophisticated, detailed casting. Our molds are prepared under
vacuum condition, minimizing imperfections, and resulting in higher quality pieces.
Use the mixing glass to prepare the silicone molding rubber
compound used to fill up the u-shaped mold frame. The quantity
of silicone molding rubber compound needed for each mold
should be calculated based on the u-shaped mold frame’s size:
Width (mm) x Height (mm) x Depth (mm) =
Quantity in grams of silicone molding rubber compound
Height
in mm
Depth
in mm
Width
in mm
Once the quantity is determined, add the catalyst. Follow the manufacturer’s specifications
to define the amount and how to manipulate the catalyst.
EXPERT TIP: Additional sizes of u-shaped mold frames may be purchased.
REMINDER: The built-in sprue former will eventually detach from the
u-shaped mold frame. Glue it back using a drop of super glue.
Attach your jewelry pattern to the sprue former using a drop
of super glue. Make sure to position it leaving at least ¼inch
from the edges of the u-shaped mold frame.
Enclose the aluminum
u-shaped mold frame using
the two molding panels,
then secure it using a rubber
band. Make sure to align the
panels to the base of the
u-shaped mold frame so that,
when secured together, the
piece firmly stands in the
upright position.
¼“ ¼“
4. PREPARE THE SILICONE
MOLDING RUBBER COMPOUND
5. MIX THE SILICONE MOLDING
RUBBER COMPOUND
9
Attach the small impeller to the central shaft on
the polycarbonate lid with the aid of the allen
key. Make sure to properly tighten the screw.
WARNING: Failure to properly tighten the
screw may result in equipment damage and
malfunction.
Connect the vacuum pump hose to the
horizontal vacuum connector on the
polycarbonate lid. Close the vertical
vacuum connector with the end cap.
Turn on the vacuum pump (manometer
should reach around 20 PSI). The mixing
glass and the polycarbonate lid will be fully
attached and sealed due to the vacuum.
Connect the polycarbonate lid’s mixer shaft
to the mixer’s motor shaft.
Turn on the mixer for 30 seconds. During
this process, the color of the silicone mix
may change.
Rest the mixing glass on a flat surface
with the silicone mix in it. Close it with
the polycarbonate lid, placing the small
impeller inside the mixing glass.
1
3
2
4
10
Turn o the mixer switch and disconnect
the polycarbonate lid and mixing glass from
its shaft.
Rest the mixing glass on a flat surface, turn
o the vacuum pump and disconnect the
hose from the horizontal vacuum connector
on the polycarbonate lid.
Pour the silicone mix inside the previously
prepared u-shaped mold frame.
Immediately clean the small impeller and
mixing glass using paper towel. Failure to
do so may result in equipment damage.
Wait for the silicone to dry in the u-shaped
mold frame. Drying time varies according to
the silicone’s manufacturer’s specifications.
Detach the polycarbonate lid from the
mixing glass. Air bubbles in the silicone
should burst, leaving a smooth and
homogeneous silicone mix.
5
7
6
MIX THE SILICONE MOLDING RUBBER COMPOUND CONT’D
6. CUT THE SILICONE MOLD
11
After the silicone dries, unmold it from the u-shaped mold frame. Remove the rubber
band and molding panels.
Use the precision knife to cut the mold in two halves, using your preferred technique.
EXPERT TIP: You may also use the
silicone mold cutting aid to assist.
Once the two halves separate, remove your jewelry pattern.
EXPERT TIP: Try cutting the silicone mold in a zigzag pattern.
ANY QUESTIONS SO FAR?
Watch our video tutorial at www.brightfuser.com
7. SILICONE MOLD WAX INJECTION USING
THE FUSER500™WAX INJECTOR
12
The Fuser500™ wax injector reaches up to 90°C. The wax heating reservoir may hold up to 1 pound
(454 grams) of wax.
WARNING: To optimize the wax injector usage, do not place more than 7 ounces (198 grams) of wax
in the heating reservoir.
Connect the Fuser500™ pressure pump to the wax injector. Connect
the pump’s hose to the pressure regulator fitting. You will use it later
to adjust the heating compartment’s pressure to inject the silicone
mold successfully.
EXPERT TIP: Pressure levels required to fill each silicone mold will
vary. Try it as needed until you find the perfect pressure for each
mold. In general, simple patterns require less pressure, while intricate
patterns require more of it. Keep a log of how much pressure may
be required per mold for future reference.
Open the top lid of the wax injector and place the wax beads
inside the heating compartment. Safely secure the top lid back
and tighten all four knobs.
Turn on the wax injector and set the temperature to the wax
manufacturer’s specifications on the digital temperature controller.
The wax will be ready to use once the heat reaches the set
temperature.
REMINDER: Make sure to replenish wax beads as necessary.
You will know that the wax level is down when the wax injector
starts discharging air rather than properly injecting wax.
EXPERT TIP: You can always filter and reuse leftover wax. Use
caution: Any debris and/or small particles present in leftover wax
may clog the injection nozzle, resulting in a complex cleaning
process.
WARNING: Do not attempt to clean the interior of the wax heating
compartment. Simply add new wax beads on top of previously
inserted wax. Failure to do so may result in equipment damage
and malfunction.
80
80
I
O
Vacuum Injection
You may use the vacuum pump to aid the wax injection. This technique is especially recommended
when working with intricate patterns:
1) Insert the pink vacuum suction needle through the silicone mold. The tip of the
needle should stop right where the mold’s cavity begins, preferably targeting a flat
side or prong. Be careful not to insert the needle’s tip too far into the mold’s cavity
as it may cause an imperfection on your wax pattern.
2) Connect the Fuser500™ vacuum pump hose to the inner lower vacuum connector in the wax injector.
3) Connect the suction silicone tube to the frontal lower vacuum connector of the wax injector.
4) Turn on the vacuum pump.
5) Follow the same steps as if for a simple injection. Remember to adjust the pressure if necessary.
8. WAX INJECTION TECHNIQUES
USING THE WAX INJECTOR
13
Simple Injection
Enclose the silicone mold (without the jewelry pattern in it) using the
two molding panels.
Position the sprue former inlet on the injection nozzle of the wax
injector. Gently push it in until the wax fills up the entire mold’s cavity.
Remove the mold from the injection nozzle.
Wait a few seconds for the wax to cool down and then unmold it.
Inspect the wax pattern for imperfections. If necessary, adjust the pressure regulator by pulling the
black knob to unlock it. Turn the knob clockwise to increase pressure, counterclockwise to decrease
pressure. You may also use the pressure pump, manually pumping for additional pressure.
If the wax pattern persistently presents flaws in a specific spot, even after adjusting the pressure,
carefully inspect your silicone mold for imperfections. If needed, create a new silicone mold.
EXPERT TIP: If the wax pattern presents imperfections in a specific point, you may
use the precision knife to cut through the silicone mold. These thin cuts will allow
for more air to be released. They should be made targeting the imperfection from
the inside of the mold’s cavity through the outside.
9. SPRUE CONFECTION AND TREE ASSEMBLY
14
EXPERT TIP: In this section, you will need a precision scale, motor oil, a low-power soldering iron,
a pyrograph, or a wax pen tool.
Sprues are the central stems used to mount wax trees. Use the sprue silicone tube to produce
your own sprues.
Cut the sprue into the size you will require. Weigh the sprue and wax patterns to determine how
much metal will be needed.
1 gram of wax = 17 grams of gold
1 gram of wax = 10 grams of silver
EXPERT TIP: Always add at least 10%
more of the required metal quantity.
12
1. Spread oil inside the sprue
silicone tube with the aid of
one of the threaded rods.
2. Place your fingertip on one
end of the sprue silicone
tube and position the other
end on the injection nozzle
of the wax injector. Gently
push it in until the wax fills
up the entire tube.
3. Wait a few seconds for the
wax to cool down and dry
out, and then unmold the
sprue by pushing it out.
Fit the sprue into the flask
base’s center hole with the
aid of a low-power soldering
iron, a pyrograph, or a wax
tool pen.
Attach your wax patterns to
the sprue with the aid of a
low-power soldering iron, a
pyrograph, or a wax pen tool.
Make sure to leave at least
¼inches between each wax
pattern so they do not touch
one another.
The Fuser500™ contains 3 flasks.
Choose the appropriate size and start
building your sprue tree following these
measurements:
• At least ¼” above the flask base.
• At least ½” below the height of the flask.
• At least ¼” from the width of the flask.
¼“
¼“¼“
½“
SPRUE CONFECTION AND TREE ASSEMBLY CONT’D
Before enclosing the wax tree with the flask, make sure to create at least 2 internal vacuum
channels in it:
1. Cut the pink wax sheet into thin strips
of approximately ¼inch.
2. Attach the strips to the interior of the
flask, vertically positioned. The strips
should cover ¾of the height of the
flask, leaving the bottom ¼empty.
Once you are done assembling your wax tree, enclose it with
the flask, making sure that the strips face up without touching
the bottom, and place it on top of the flask base. Position both
threaded rods, and set the flask top. Secure the casting base
system by tightening both nuts.
Front View Top View
¼
¾
15
WE HOPE YOU ARE ENJOYING
YOUR EXPERIENCE!
Please let us know any feedback by sending an email to info@brightfuser.com
10. FLASK PREPARATION USING
THE MIXER AND VACUUM PUMP
16
EXPERT TIP: In this section, you will need a precision scale, investment powder, water, a small
screwdriver, and grease.
Attach the large impeller to the center shaft of
the polycarbonate lid with the aid of the allen
key. Make sure to tighten the screw properly.
WARNING: Failure to properly tighten the screw
properly may result in equipment damage and
malfunction.
Rest the flask system on a flat surface and
enclose it with the vacuum chamber. Place
the rubber filling funnel on top (inside the
vacuum chamber).
Weigh the investment powder according
to the size of the used flask being used:
• Measure the quantity of water needed according to the
manufacturer’s specifications.
• Rest the mixing chamber on a flat surface. Pour water in it,
followed by the investment powder. Always add water first
to ensure a more homogeneous mix.
• Close the mixing chamber with the polycarbonate lid, with
the large impeller inside the chamber.
SMALL FLASK
Approximately 100 grams
of investment powder
MEDIUM FLASK
Approximately 190 grams
of investment powder
LARGE FLASK
Approximately 390 grams
of investment powder
1
3
2
17
FLASK PREPARATION USING THE MIXER
AND VACUUM PUMP CONT’D
Turn the vacuum chamber upside down,
with the flask system in it, and rest it on
the small circle of the polycarbonate lid.
Connect the vacuum pump hose to the
horizontal connector of the polycarbonate lid.
Connect the center shaft of the polycarbonate
lid to the motor shaft of the mixer.
Connect one end of the by-pass silicone
tube to the vacuum chamber connector
and the other end to the vertical connector
of the polycarbonate lid.
Turn on the vacuum pump. As soon as the
manometer reaches 20 PSI, turn on the mixer
for 1 minute.
Turn o the mixer and disconnect the
polycarbonate lid from the motor shaft of
the mixer.
4
6
5
7
18
FLASK PREPARATION USING THE MIXER
AND VACUUM PUMP CONT’D
Keep the vacuum pump on. The mixing and vacuum chambers will be fully attached and sealed
due to the vacuum.
Turn the mixing chamber upside down counterclockwise so that the investment flows through
the filling funnel into the vacuum chamber.
WARNING: Make sure to face the vacuum chamber connector and turn the mixing chamber
upside down counterclockwise, so the investment flows directly to the vacuum chamber.
Do not turn the mixing chamber clockwise, where the investment would flow from the mixing
chamber to the vacuum connector. Doing so may result in equipment damage and malfunction.
8
Once all of the investment fills the flask
inside the vacuum chamber, rest it on a
flat surface. Hold the mixing chamber
and turn o the vacuum pump.
Hold with
your hand
Hold with
your hand
While holding the polycarbonate lid, detach the
vacuum hose (1), and then detach the by-pass
silicone tube (2). Pull the chambers apart.
9 10
1
2
19
FLASK PREPARATION USING THE MIXER
AND VACUUM PUMP CONT’D
Immediately thoroughly wash the mixing chamber,
large impeller, and polycarbonate lid with room
temperature water. Dry it using paper towel. Failure
to do so may result in equipment damage.
Use the lecron carver to dig approximately ¼
inch to meet the sprue tree’s base. Remember,
when you turned the mixing chamber upside
down, the sprue tree base became the flask’s
top. Also dig approximately ⁄ inch on the
opposite side of the flask. This will later facilitate
the metal inclusion under vacuum.
Wait approximately 15-20 minutes.
Disassemble the vacuum chamber and
gently touch the investment, making sure
it feels firm before proceeding.
Wait for the investment to dry out
completely. Drying time varies according
to the manufacturer’s specifications.
EXPERT TIP: The usual drying time for
a small flask is approximately 2 hours.
11
13
12
14
WARNING: You must clean the polycarbonate lid’s shaft every 15 uses. Failure to do so may result in
product damage. Use the allen key to remove the lock pin. Use a small screwdriver to remove the lock
ring that holds the shaft. Gently pull the shaft and clean the excess grease and investment residues
using a clean cloth or paper towel. Then, place the cloth or paper on the tip of the screwdriver and
clean the shaft’s fitting. Once clean, apply a generous amount of grease to the shaft, especially to its 2
rubber rings, then fit it back in. Secure the lock pin using the allen key and place the lock ring back into
place. Clean the entire piece using a clean cloth or paper towel to remove any excess grease.
Visit www.brightfuser.com for the instructional video.
Dig the
investment
11. FLASK BURNOUT USING THE KILN
20
Once the investment is completely dry, place the flask(s) inside the Fuser500™ kiln. Position
flask(s) with the dug hole facing up or sideways. Never position the hole facing down. Close
the lid and turn on the kiln. Your kiln’s lid will not fully close due to ventilation purposes.
EXPERT TIP: Do not let the flasks touch the front and back walls of the Fuser500™ kiln where the
heating elements are located. Failure to do so may cause flaws and porosities to the investment.
Both sidewalls may be used as a support system to fit more than one flask.
Burnout time varies between 3 ½and 4 hours
and only draws less than 4 amps when operating.
Do not leave the flask(s) past 3 ½up to 4 hours; otherwise, they may overburn and cause flaws
and porosities to the investment.
During this process, the interior of the kiln and investment will turn black. When the wax calcines,
everything will return to its regular color, and the investment cavity will be glowing red. This is
when you should prepare to pour in the metal.
WARNING: Do not open the kiln during the burnout process. Do not touch the interior of
the kiln. Do not use the kiln for any other purpose. Use caution and common sense when
operating the Fuser500™ kiln. Misuse may result in product damage and severe injury.
Kiln capacity:
1 large flask
L
M
SS
S
S
S
Up to 1 medium flask
and one 1 small flask
Up to 4 small flasks
Table of contents
