Tooling and method for manufacturing a fiber optic array

A fiber optic array, comprising:

• a plurality of optical fibers, each optical fiber including a buffer tube portion surrounding the optical fiber;
• a substrate for supporting the plurality of optical fibers, the substrate defining a first end and a second end and a first outer edge and a second outer edge perpendicular to the first and second ends;
• and
• a plurality of spaced-apart channels defined by the substrate, the channels defining parallel portions at the first end of the substrate and a fiber clamp provided at the second end of the substrate, the spaced-apart channels provided in a stacked arrangement extending from the first outer edge to the second outer edge, wherein the spaced-apart channels define open top ends for receiving the optical fibers therein such that the parallel portions of the channels defined at the first end of the substrate are sized to frictionally receive and secure the buffer tube portions of the optical fibers without an additional structure covering top sides of the optical fibers;
• wherein the plurality of optical fibers are positioned on the substrate such that the optical fibers extend from being spaced-apart via the channels to a consolidated arrangement wherein the fibers are layered next to each other, the fiber clamp securing the consolidated fibers at the second end of the substrate, and wherein the plurality of optical fibers are positioned within the spaced-apart channels such that a majority of each optical fiber is uncovered along a length thereof as the optical fibers extend from the first end to the second end of the substrate.