Overmolded optical circuits

A method of preparing an overmolded optical fiber assembly comprising:

• (a) flowing a self-leveling fluoropolymer in a bottom mold, said bottom mold defining a bottom overmold cavity having a bottom surface, wherein flowing said self-leveling fluoropolymer in said bottom mold does not involve injection molding;
• (b) placing at least one flexible optical circuit in said bottom mold, said at least one flexible optical circuit having a substrate and a plurality of fibers adhered to said substrate, said substrate being suspended over said bottom surface to define a first space between said substrate and said bottom surface;
• (c) placing a top mold over said substrate, said top mold defining a top overmold cavity and a top surface and a port defined in said top surface to access said top overmold cavity, said substrate defining a second space between said top surface and said substrate;
• (d) flowing a self-leveling fluoropolymer through said port to fill at least a portion of said second space, wherein flowing said self-leveling fluoropolymer through said port does not involve injection molding;
• and
• (e) removing said bottom and top molds to release said overmolded optical circuit, wherein said overmolded optical circuit is flexible.