Method for aligning bore forming pins during molding of multi-fiber optical connector ferrules

A method of aligning and retaining a plurality of fiber bore forming pins and at least one guide bore forming pin in precise relation to each other during molding of a multi-fiber ferrule, the method comprising the steps of:

• (a) retaining each of the plurality of fiber bore forming pins in a respective one of a plurality of fiber bores, each of the plurality of fiber bores extending through a respective one of a plurality of fiber bore blocks;
• (b) adjoining the plurality of fiber bore blocks together in an array such that the plurality of fiber bores are parallel to each other and defining an axial direction and wherein adjoining surfaces are defined between adjacent fiber bore blocks;
• (c) retaining each of the at least one guide bore forming pin in a respective one of at least one guide bore, each guide bore extending through a respective one of at least one guide bore block;
• (d) adjoining the at least one guide bore block to the array of fiber bore blocks such that the guide bore is oriented generally parallel with the fiber bores and wherein adjoining surfaces are defined between the at least one guide bore block and adjacent fiber bore blocks;
• and
• (e) machining the adjoining surfaces between the fiber bore blocks and between the guide bore block and the array of fiber bore blocks such that when the fiber bore blocks and the at least one guide bore block are assembled together, the desired relationships between successive fiber bores and between the fiber bores and the at least one guide bore are achieved.