Molded star coupler and method of making same

A method for making a molded star coupler comprising the steps of:

• molding a first optical portion having a major surface, a first end surface and a second end surface, the major surface including a free space area, a first plurality of grooves with a first plurality of ends and a second plurality of ends, a second plurality of grooves with a first plurality of ends a second plurality of ends molded simultaneously with the major surface of the first optical portion,
• i. molding the first plurality of ends of the first plurality of grooves at the first end surface of the molded first optical portion and the second plurality of ends connected to the free space area with the first plurality of grooves extending therebetween, thus interconnecting the first plurality of grooves to the free space region, and
• ii. molding the first plurality of ends of the second plurality of grooves at the second end surface of the molded first optical portion and the second plurality of ends connected to the free space area with the second plurality of grooves extending therebetween, thus interconnecting the first plurality of ends of the second plurality of core regions to the free space region;
• and
• applying an optical media to the surface of the first optical portion filling the first and second plurality of grooves and the free space area, thereby fabricating a molded star coupler.