A precision mold insert and method for manufacturing angled or angled and
bumpered multi-fiber ferrules. The precision mold insert includes an
angled end face forming portion, one or more optional bumper forming
portions, one or more fiber bores for receiving one or more fiber bore
forming pins, and one or more guide pin holes for receiving one or more
guide pin hole forming pins. A method for manufacturing a precision mold
insert for molding angled or angled and bumpered multi-fiber ferrules
utilizing electrical discharge machining (EDM) process and/or a poly
crystalline diamond (PCD) grinding tool is provided. The mold insert is
used to produce a multi-fiber ferrule having a pre-molded angled end face
that is not machined, polished or otherwise altered subsequent to the
molding process. The ferrule may also include bumpers for polishing end
portions of optical fibers positioned within the fiber bores without
altering the angled end face.