Molded optical connectors with zero-draft mechanical alignment features

A molded optical cradle configured to mate with a mating optical ferrule and configured to align the mating optical ferrule to an optical device, the molded optical cradle comprising:

• a top major surface;
• an opposing bottom major surface, the top major surface and bottom major surface defining a thickness direction of the molded optical cradle therebetween;
• and
• a recess configured to accept the mating optical ferrule, the recess extending between the top major surface and the bottom major surface in the thickness direction and comprising a plurality of inner side surfaces;
• each inner side surface of the plurality of inner side surfaces comprising a plurality of first side surface portions making a first angle greater than or equal to 1 degree with the thickness direction, the first angle assisting in a removal of the molded optical cradle from a corresponding mold;
• and
• a plurality of second side surface portions disposed on the inner side surface and extending outwardly from at least some of the plurality of first side surface portions, each second side surface portion having a second angle of 0 degrees with the thickness direction and a maximum dimension of 200 microns, such that when the molded optical cradle is mated with the mating optical ferrule, at least some of the second, but none of the first, side surface portions contact corresponding side surface portions of the mating optical ferrule, the contact covering at least 50% of a surface area of each contacting second side surface portion.

An optical assembly comprising:

• a molded optical ferrule comprising:
• a top surface comprising an attachment area for attaching to an optical waveguide and a light redirecting member for receiving light from the optical waveguide attached to the attachment area along a first direction and redirect the received light along a different second direction;
• a bottom surface opposite the top surface and comprising an exit window, the top and bottom surfaces defining a thickness direction of the molded optical ferrule therebetween, the light redirected by the light redirecting member exiting the molded optical ferrule through the exit window;
• and
• a plurality of side surfaces joining the top and bottom surfaces and comprising:
• a plurality of first side surface portions making a first angle greater than or equal to 1 degree with the thickness direction of the molded optical ferrule, the first angle assisting in a removal of the molded optical ferrule from a corresponding mold;
• and
• one or more second side surface portions
• disposed on the plurality of side surfaces and extending outwardly from at least some of the plurality of first side surface portions, each second side surface portion having a second angle of 0 degrees with the thickness direction of the molded optical ferrule;
• and
• an optical cradle comprising a recess configured to accept the molded optical ferrule therein and to align the molded optical ferrule to an optical device, the recess extending between a first major surface and a second major surface of the optical cradle in a thickness direction of the optical cradle and comprising a plurality of inner side surfaces;
• wherein at least some of the one or more second side surface portions of the molded optical ferrule make direct surface-to-surface contact with at least some of the plurality of inner side surfaces of the optical cradle when mated, none of the plurality of first side surface portions of the molded optical ferrule contact the plurality of inner side surfaces in the mated state, and the direct contact covers at least 50% of a surface area of each contacting second side surface portion.