Method for making optical fiber connector

A method for making an optical fiber connector, the optical fiber connector comprising a blind hole portion and a lens portion connected to the blind hole portion, the blind hole portion comprising a plurality of blind holes each for receiving an optical fiber, the lens portion comprising a flat optical surface located at an end thereof, and a plurality of lens caps formed on the optical surface aligned with the respective blind holes, the method comprising:

• providing a mold, the mold comprising a first mold portion having a plurality of inserts each configured for insert molding a blind hole preform, and a second mold portion having a flat molding surface for forming a flat optical surface, and a plurality of curved molding surfaces for forming the lens caps of the optical fiber connector;
• forming the blind hole preform using the inserts and forming the flat optical surface on the blind hole preform using the flat molding surface, the blind hole preform having a bottom enclosed by the flat optical surface;
• providing a non-contact detection instrument adjacent to the flat optical surface, the non-contact detection instrument configured for projecting a light beam to the bottom of each of the blind hole preforms through the flat optical surface, and generating a coarseness factor image of the bottom of each of the blind hole performs;
• analyzing the coarseness factor image to determine whether the coarseness factor of the bottom of the corresponding blind hole preform is acceptable;
• modifying the corresponding insert if the coarseness factor of the bottom of one blind hole preform is not acceptable;
• and
• aligning the curved molding surfaces with the respective inserts to form the lens caps on the flat optical surface.

A method for making an optical fiber connector, the method comprising:

• molding an optical fiber connector preform, the optical fiber connector preform including a blind hole exposed at a first side and a lens portion located at an opposing second side thereof, the lens portion aligned with the blind hole and having a flat outer surface facing away from the blind hole and an inner surface located at a bottom of the blind hole;
• observing the inner surface through the lens portion from the second side to determine whether the optical quality of the inner surface is acceptable;
• modifying the inner surface if the optical quality of the inner surface is not acceptable;
• and
• forming a lens cap on the flat outer surface if the optical quality of the inner surface is acceptable, the lens cap having a curved outer surface.