Patent Publication Number: US-2023144989-A1

Title: Optical ferrules and optical ferrule molds

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application is a continuation filing of U.S. application Ser. No. 17/716,052, filed Apr. 8, 2022, now allowed, which is a continuation of Ser. No. 16/946,248, filed Jun. 12, 2020, issued as U.S. Pat. No. 11,327,244, which is a divisional of U.S. application Ser. No. 15/758,743, filed Mar. 9, 2018, issued as U.S. Pat. No. 10,746,942, which is a national stage filing under 35 C.F.R. 371 of PCT/US2016/056324, filed Oct. 11, 2016, which claims the benefit of U.S. Provisional Application No. 62/239,996, filed Oct. 12, 2015, the disclosures of which are incorporated by reference in their entireties herein. 
    
    
     TECHNICAL FIELD 
     This disclosure relates generally to optical ferrules and to molds for making optical ferrules. 
     BACKGROUND 
     Optical connectors can be used for optical communications in a variety of applications including telecommunications networks, local area networks, data center links, and internal links in computer devices. Expanded optical beams may be used in connectors to provide an optical connection that is less sensitive to dust and other forms of contamination and so that alignment tolerances may be relaxed. Generally, an expanded beam is a beam that is larger in diameter than the core of an associated optical waveguide (usually an optical fiber, e.g., a multi-mode fiber for a multi-mode communication system). The connector is generally considered an expanded beam connector if there is an expanded beam at a connection point. The expanded beam is typically obtained by diverging a light beam from a source or optical fiber. In many cases, the diverging beam is processed by optical elements such as a lens or mirror into an expanded beam that is approximately collimated. The expanded beam is then received by focusing of the beam via another lens or mirror. Optical connectors including expanded beam optical connectors can include optical ferrules that include elements for receiving and securing optical waveguides, elements for affecting light from the optical waveguides, and features for aligning the optical ferrule to a mating ferrule. 
     BRIEF SUMMARY 
     Some embodiments are directed to a molded unitary optical ferrule that includes one or more parting line artifacts, the one or more parting line artifacts including a parting line artifact extending substantially around an external perimeter of the unitary ferrule. The parting line artifacts divide the surface of the optical ferrule along a thickness axis into a first section and an opposing second section. The first section of the surface includes one or more elements configured for receiving and securing a optical waveguide, one or more elements configured for affecting one or more characteristics of light from the optical waveguide while propagating the light within the unitary ferrule and one or more first alignment features that, when the ferrule is mated with a mating ferrule, control translation of the ferrule along a first lateral axis orthogonal to the thickness axis, translation of the ferrule along a second lateral axis orthogonal to both the thickness axis and the first lateral axis, and rotation of the ferrule around the thickness axis. The second section includes at least one second alignment feature that, when the ferrule is mated with a mating ferrule, controls translation of the ferrule along the thickness axis, and rotation of the ferrule around the first and second lateral axes. 
     According to some embodiments, a molded unitary optical ferrule includes one or more parting line artifacts, including a parting line artifact extending substantially around an external perimeter of the unitary ferrule, the parting line artifacts dividing a surface of the optical ferrule along a thickness axis into a first section and an opposing second section. The ferrule includes one or more elements configured for receiving and securing an optical waveguide, one or more elements configured for affecting one or more characteristics of light from the optical waveguide while propagating the light within the unitary ferrule, and at least one planar surface configured to make contact with a planar mating surface of a mating ferrule during mating of the ferrule. The ferrule also includes one or more alignment features that, when the ferrule mates with the mating ferrule, primarily control rotation of the ferrule around the thickness axis, translation of the ferrule along a first lateral axis orthogonal to the thickness axis, and translation of the ferrule along a second lateral axis orthogonal to the thickness axis and to the first lateral axis. The first section of the ferrule contains the one or more elements configured for receiving and securing an optical waveguide, the one or more elements configured for affecting one or more characteristics of light, and the alignment features and the second section of the ferrule includes the planar surface. 
     In some embodiments, a molded unitary optical ferrule includes one or more parting line artifacts, including a parting line artifact extending substantially around an external perimeter of the unitary ferrule, the parting line artifacts dividing a surface of the optical ferrule along a thickness axis into a first section and an opposing second section. The ferrule includes one or more elements configured for receiving and securing an optical waveguide, one or more elements configured for affecting one or more characteristics of light from the optical waveguide while propagating the light within the unitary ferrule, a sliding surface that, during mating of the ferrule and a mating ferrule, facilitates sliding of the ferrule against a sliding surface of the mating ferrule along a ferrule mating axis, when the ferrule is mated with the mating ferrule, the sliding surface is configured to control rotation of the ferrule around the ferrule mating axis, translation of the ferrule along a thickness axis orthogonal to the ferrule mating axis, and rotation of the ferrule around a lateral axis orthogonal to the ferrule mating axis and the thickness axis, and one or more alignment features that, when the ferrule is mated with the mating ferrule, primarily control translation of the ferrule along the ferrule mating axis, translation of the ferrule along the lateral axis, and rotation of the ferrule around the thickness axis. The first section of the surface includes the receiving and securing elements, the light affecting elements, and the alignment features and the second section of the surface includes the sliding surface. 
     Some embodiments are directed to an injection mold that includes a first mold side and a second mold side that fit together to define a cavity for molding a unitary optical ferrule, and configured to separate along a parting axis. The unitary optical ferrule is molded with a thickness axis parallel to the parting axis. The first side of the mold includes first mold features configured to mold: a plurality of first elements configured for receiving and securing an optical waveguide and for affecting one or more characteristics of light from the optical waveguide while propagating the light within the unitary ferrule and one or more first alignment features that, when the ferrule is mated with a mating ferrule, control translation of the ferrule along a first lateral axis orthogonal to the thickness axis, translation of the ferrule along a second lateral axis orthogonal to both the thickness axis and the first lateral axis, and rotation of the ferrule around the thickness axis. The second mold side includes second mold features configured to mold one or more second alignment features that, when the ferrule is mated with a mating ferrule, control translation of the ferrule along the thickness axis, and rotation of the ferrule around the first and second lateral axes. 
     Embodiments are directed to an injection mold including a first mold side and a second mold side that fit together to define a cavity for molding a unitary optical ferrule and configured to separate along a parting axis. The unitary optical ferrule is molded with a thickness axis parallel to the parting axis. The first mold side has first mold features configured to mold: a plurality of first elements configured for receiving and securing an optical waveguide and for affecting one or more characteristics of light from the optical waveguide while propagating the light within the unitary ferrule and one or more first alignment features that, when the ferrule is mated with a mating ferrule, control translation of the ferrule along a first lateral axis orthogonal to the thickness axis, translation of the ferrule along a second lateral axis orthogonal to both the thickness axis and the first lateral axis, and rotation of the ferrule around the thickness axis. The second mold side includes second mold features configured to mold one or more second alignment features that, when the ferrule is mated with a mating ferrule, control translation of the ferrule along the thickness axis, and rotation of the ferrule around the first and second lateral axes. 
     Some embodiments involve an optical ferrule that includes one or more receiving elements and one or more light affecting elements. Each receiving element is configured for receiving and securing an optical waveguide. Each light affecting element includes a light redirecting feature comprising a curved lens in an optical path of light from the optical waveguide, the receiving element configured to align the waveguide with the lens, and a planar region at least partially surrounding the lens and comprising a first reference surface for the lens. The light affecting element includes an intermediate surface that extends between the receiving element and the light redirecting feature and comprising a second reference surface, wherein the first reference surface is disposed at a predetermined angle with respect to the second reference surface, the angle determining a positional relationship between the lens and the waveguide. 
     According to some embodiments, an optical ferrule includes one or more receiving elements and one or more light affecting elements. Each receiving element is configured for receiving and securing an optical waveguide. Each light affecting element comprises a light redirecting feature. Each light redirecting feature comprises a curved lens in an optical path of light from the optical waveguide, the receiving element configured to align the waveguide with the lens and a planar region at least partially surrounding the lens the planar region comprising a first reference surface for the lens. The first reference surface is disposed at an angle with respect to a second reference surface of the optical ferrule; the angle determines a positional relationship between the lens and the waveguide. 
     Some embodiments involve an injection mold. The mold includes a first mold side and a second mold side that fit together to define a cavity for molding a unitary optical ferrule. The cavity is configured to separate along a parting axis, the unitary optical ferrule being molded with a thickness axis parallel to the parting axis. The first mold side includes mold features configured to mold one or more light affecting elements, each light affecting element a light redirecting feature comprising a curved lens in an optical path of light from the optical waveguide, the receiving element configured to align the waveguide with the lens and a planar region at least partially surrounding the lens and comprising a first reference surface for a position of the lens. The first reference surface is disposed at an angle with respect to a second reference surface of the optical ferrule that determines a positional relationship between the lens and the waveguide. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG.  1 A  illustrates a first side of the optical ferrule in accordance with some embodiments; 
         FIG.  1 B  illustrates a second side of the ferrule of  FIG.  1 A ; 
         FIG.  1 C  illustrates a flash parting line artifact; 
         FIG.  1 D  illustrates a step parting line artifact; 
         FIGS.  2 A and  2 B  illustrate first and second sides of a mold according to some embodiments. 
         FIGS.  3 A through  3 D  show a unitary optical ferrule made using the mold of  FIGS.  2 A and  2 B ; 
         FIGS.  4 A and  4 B  illustrate first and second sides of a mold according to some embodiments; 
         FIG.  4 C  shows a second mold side that includes mold features configured to mold multiple planar surfaces in accordance with some embodiments 
         FIGS.  5 A through  5 D  show first and second sides of a unitary optical ferrule made using the mold of  FIGS.  4 A and  4 B ; 
         FIG.  5 E  illustrates the second side of a unitary optical ferrule made using the second mold side shown in  FIG.  4 C ; 
         FIGS.  6 A and  6 B  illustrate first and second sides of a mold according to some embodiments; 
         FIGS.  7 A and  7 B  show first and second sides of a unitary optical ferrule made using the mold of  FIGS.  6 A and  6 B ; 
         FIG.  7 C  is a view of a perimeter parting line artifact of the optical ferrule of  FIGS.  7 A and  7 B ; 
         FIGS.  8 A and  8 B  illustrate first and second sides of a mold according to some embodiments; 
         FIGS.  9 A and  9 B  show a unitary optical ferrule made using the mold of  FIGS.  8 A and  8 B ; 
         FIG.  10    depicts mated unitary optical ferrules having multiple parallel planar surfaces in accordance with some embodiments; 
         FIGS.  11 A through  11 C  illustrate first and second sides of a mold according to some embodiments; and 
         FIGS.  12 A through  12 E  show a unitary optical ferrule made using the mold of  FIGS.  11 A through  11 C . 
     
    
    
     The figures are not necessarily to scale. Like numbers used in the figures refer to like components. However, it will be understood that the use of a number to refer to a component in a given figure is not intended to limit the component in another figure labeled with the same number. 
     DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS 
     Optical connectors including expanded beam optical connectors can include optical ferrules (also referred to herein as “light coupling units” or “LCUs”) that are formed as unitary, molded structures. Some embodiments described herein involve molded optical ferrules and molds for making optical ferrules. Molding ferrules involves the use of two primary mold parts which are referred to herein as the “first mold side” and the “second mold side”. The first mold side includes first mold features configured to mold a first set of the features of the optical ferrule. The second mold side includes second mold features configured to mold a second set of the features of the optical ferrule. When the mold is operated, the two halves are brought together along what is referred to herein as the “parting axis”, the first side and the second side define a cavity for molding a unitary optical ferrule. A flowable mold material is injected or otherwise placed into the cavity and hardens, e.g., due to cooling of the mold material, to form the unitary ferrule. The mold halves are then separated along the parting axis to allow the ferrule to be removed. Some materials useful for molded ferrules include thermoplastic and thermosetting polymers, ceramics, metals, glasses, etc. 
       FIG.  1 A  and  FIG.  1 B  are diagrams of a unitary optical ferrule  100 . A unitary optical ferrule is a single piece structure that includes one or more elements for receiving and securing a waveguide, one or more elements for affecting light from the waveguide, and one or more alignment features. 
       FIG.  1 A  illustrates a first side  101  of the optical ferrule  100  and  FIG.  1 B  illustrates a second side  102  of the ferrule  100 . For purposes of discussion and without limitation to any particular orientation of the ferrule, the first side  101  may be designated as the top side and the second side  102  as the bottom side. The optical ferrule  100  includes at least one element  103  for receiving and securing an optical waveguide  104  and at least one element  105  for affecting one or more characteristics of light from the optical waveguide  104  while propagating the light within the optical ferrule  100 . The optical ferrule  100  includes one or more alignment features  111 - 114  for aligning the optical ferrule  100  with a mating optical ferrule (not shown in  FIGS.  1 A and  1 B ). 
     Alignment of the optical ferrule  100  with the mating optical ferrule is achieved by controlling six mechanical degrees of freedom in three dimensions, the six mechanical degrees of freedom being translation along and rotation around each of three orthogonal axes  121 ,  122 ,  123 . For purposes of discussion, axis  121  is referred to herein as the first lateral axis, axis  122  is referred to herein as the second lateral axis, and axis  123  is referred to as the thickness axis. Axis  121  can be the ferrule mating axis. The six mechanical degrees of freedom controlled after mating the ferrule to a mating ferrule include translation along the first lateral axis  121 , translation along the second lateral axis  122 , translation along the thickness axis  123 , rotation around the first lateral axis  121 , rotation around the second lateral axis  122 , and rotation around the thickness axis  123 . In the example shown in  FIGS.  1 A and  1 B , when the ferrule  100  is mated with a mating ferrule, forward stops  111  contact forward stops of the mating ferrule to control translation along the first lateral axis  121 ; pin  112  of ferrule  100  engages with a socket of the mating ferrule and socket  113  of ferrule  100  engages with a pin of the mating ferrule to control translation of the ferrule  100  along the second lateral axis  122 . The forward stops  111 , and/or the pin  112  and socket  113  may be used to control the rotation of the ferrule around the thickness axis  123 . When the ferrule  100  is mated with a mating ferrule, the surface  114  of ferrule  100  engages with a surface of the mating ferrule to control translation of the ferrule  100  along the thickness axis  122 , rotation of the ferrule around the first lateral axis  121 , and rotation of the ferrule around the lateral  122  axis. In some embodiments, the socket  113  is formed by at least a portion of a hole that extends through the thickness of the ferrule  100 . 
     Additional information regarding optical ferrules having the alignment features disclosed herein is provided in commonly owned and concurrently filed U.S. Patent Application Ser. 62/240,069, having the title “Optical Ferrules,” and identified by Attorney Docket No. 76982US002, which is incorporated herein by reference. 
     The error in alignment of the mold sides can be significant, e.g., on the order of about 10 μm or more. If the receiving and securing elements, the light affecting elements, and mechanical alignment features are not molded by a single side of the mold, the receiving and securing elements and the light affecting elements may be misaligned with the alignment features. When such a defective ferrule is mated with a mating ferrule, the alignment features cause the receiving and securing elements and the light affecting elements to be improperly aligned with the mating ferrule, thereby increasing the optical insertion loss of the connector. 
     Some embodiments disclosed herein involve a mold for molding an optical ferrule, the mold including a first mold side and a second mold side that fit together to define a cavity for molding a unitary optical ferrule. The unitary optical ferrule is molded with a thickness axis parallel to the parting axis of the mold. In some embodiments, the first mold side may comprise a single mold insert that includes first mold features configured to mold one or more elements configured for receiving and securing an optical waveguide and one or more elements configured for affecting characteristics of light from the optical waveguide while propagating the light within the unitary ferrule. The first mold features are also configured to mold one or more first alignment features that, when the ferrule is mated to a mating ferrule, primarily control translation of the ferrule along lateral axes orthogonal to the thickness axis, and rotation of the ferrule around the thickness. The second mold side includes second mold features that are configured to mold one or more second alignment features that, when the ferrule is mated with a mating ferrule, primarily control translation of the ferrule along the thickness axis, and rotations of the ferrule around the lateral axes. 
     In some embodiments, the second alignment feature includes a planar surface that is normal to the parting axis of the mold. In these embodiments, the molded ferrule can be insensitive to nominal misalignment of the mold sides. In some embodiments, one of the lateral axes is a mating axis of the ferrule. 
     Some embodiments disclosed herein are directed to a unitary optical ferrule made by the mold sides discussed above, the optical ferrule molded with a thickness axis parallel to the mold parting axis, and including one or more elements configured for receiving and securing an optical waveguide and one or more elements for affecting one or more characteristics of light from the optical waveguide while propagating the light within the unitary ferrule. The optical ferrule includes one or more first alignment features that, when the ferrule is mated with a mating ferrule, control translation of the ferrule along lateral axes orthogonal to the thickness axis, and rotation of the ferrule around the thickness axis. The optical ferrule includes at least one second alignment feature that, when the ferrule is mated with a mating ferrule, controls translation of the ferrule along the thickness axis, rotation of the ferrule around the lateral axes. The surface of the optical ferrule can be divided along the thickness axis into a first section of the surface and a second section of the surface. The first section of the ferrule contains the receiving and securing elements, the light affecting elements, and the first alignment features and the second section of the ferrule includes the second alignment features and the light transmitting region through which light is coupled to a mated ferrule. In some embodiments the first section is molded by the first side of a mold, and the second section molded by the second side of a mold; a mold parting line artifact separates the first section of the surface from the second section of the surface. Parting line artifacts are features in the molded part that occur due to the misalignment or imperfect contact between the sides of the mold at the parting line. The artifact may take the form of a small step or molding flash. 
       FIG.  1 C  illustrates a portion of a cross sectional view of first  161  and second  162  sides of a mold and molded material  170  between the first and second mold sides  161 ,  162 . A flash parting line artifact  171  occurs where the molded material  170  penetrates a small gap between the mold sides  161 ,  162 .  FIG.  1 D  illustrates a portion of a cross sectional view of first  181  and second  182  sides of a mold  180  with a mold material  190  between the first and second mold sides  181 ,  182 . A flash parting line artifact  191  occurs where the mold material  190  penetrates a small gap between the mold sides  181 ,  182 . A step parting line artifact  192  occurs where the second side of the mold includes a vertical wall that is slightly misaligned with the vertical wall of the first side and the molded material penetrates a small gap between mold sides  181 ,  182 . 
       FIGS.  2 A and  2 B  illustrate first and second sides  201 ,  202  of a mold, respectively, according to some embodiments. Note that the figures of the mold sides presented herein are schematic and are intended to facilitate understanding of the various embodiments. In these schematic diagrams, some features that are not necessary to understand concepts of the embodiments have been omitted, e.g., extraction pins, optional multiple inserts, and multiple cavities, etc. Those skilled in the art of injection molding will understand that these features may be present in actual molds.  FIGS.  3 A through  3 D  show a unitary optical ferrule  300  made using the mold of  FIGS.  2 A and  2 B . The first mold side  201  includes first mold features  203 ,  205 ,  211 ,  212 ,  213  and the second mold side  202  includes second mold feature  214  and  217 . Mold features  203  of mold side  201  are configured to mold one or more elements  303 , e.g., grooves, of the optical ferrule  300  configured for receiving and securing an optical waveguide. Mold features  205  are configured to mold one or more elements  305  of the optical ferrule  300  configured for affecting characteristics of light from the optical waveguide while propagating the light within the optical ferrule  300 . Although optical ferrule  300  includes multiple receiving and securing elements  303  and multiple light affecting elements  305 , some unitary optical ferrules can include a single receiving and securing element  303  and a single light affecting element  305 . 
     The first mold side  201  includes mold features  211 ,  212 ,  213  configured to mold one or more first alignment features  311 ,  312 ,  313 . When mated with a mating optical ferrule (not shown), alignment features  311  of the optical ferrule  300  control translation of the ferrule  300  along a first lateral axis  121 . Features  311  shown in the example optical ferrule  300  of in  FIGS.  3 A through  3 D  are forward stops that engage with forward stops of a mating ferrule to set the mated distance between light affecting elements of the optical ferrule and light affecting elements of the mating ferrule. The forward stops  311 , when engaged with forward stops of the mating ferrule, also control rotation of the optical ferrule  300  around the thickness axis  123 . In this example, the forward stops  311  are located along a line  126  on the horizontal mating surface  314 , the line  126  passing through the centers of the optical beams. The forward stops  311  are formed by the first side  201  of the mold. 
     Mold features  212 ,  213  are configured to mold alignment features  312 ,  313  in the optical ferrule  300 . In the example ferrule shown in  FIGS.  3 A through  3 D , alignment feature  312  is a pin that fits into a compatible socket of a mating ferrule. Alignment feature  313  is a socket. A portion  313   a  of the socket is molded by mold feature  213   a  and is configured to receive a compatible pin of the mating ferrule. The pin and socket  312 ,  313  control translation of the optical ferrule  300  along the second lateral axis  122  and may also control rotation of the optical ferrule around the thickness axis  123 . Feature  312  may be designed such that only the sides of the pin  312  can come into contact with the mating socket, providing a lateral stop on either side of the pin  312  and thereby controlling translation along the second lateral axis  122 . The pin  312  is designed to be slightly narrower that the socket  313  to allow for manufacturing tolerances. Optionally, compliant features (not shown) could be designed into the pin and/or socket to allow for manufacturing tolerances. In some embodiments, the compliant features may provide flexible alignment. The pin or the socket, or both, can be fitted with compliant side features that facilitate centering the pin in the socket. 
     In some embodiments, the first side of the mold  201  is a single, unitary mold insert configured to mold the first mold features, thereby assuring consistent and accurate alignment of the receiving and securing elements, light affecting elements, and first alignment features in the molded ferrules. 
     The second mold side  202  includes at least one mold feature  214   b  configured to mold at least one second alignment feature  314  that, when the ferrule  300  is mated with a mating ferrule, controls translation of the ferrule  300  along the thickness axis  123 , rotation of the ferrule  300  around the first lateral axis  121 , and rotation of the ferrule  300  around the second lateral axis  122 . In the example ferrule  300  shown in  FIGS.  3 A through  3 D , alignment feature  314  is a planar surface that controls three degrees of mechanical freedom of the optical ferrule. When making the ferrule  300 , mold sides  201  and  202  are brought together through relative motion of the mold sides  201 ,  202  along the parting axis  125 . Surface  214   b  is preferably normal to the direction of relative motion of the first and second mold sides (parting axis  125 ), and being planar, is insensitive to lateral misalignment of the mold sides. 
     The top and bottom surface  390  of optical ferrule  300  is formed by the first mold side  201  and the second mold side  202 . The complete surface  390  can be divided into a first section  391  which is molded by the first mold side  201  and a second section  392  opposite the first section  391  that is molded by the second mold side  202 . The first section  391  of the surface  390  of the ferrule  300  includes those features  303 ,  305 ,  311 ,  312 ,  313  that are molded by mold features  203 ,  205 ,  211 ,  212 ,  213  of the first side  201  of the mold. The second section  392  of the surface  390  of the ferrule  300  includes the features  314  and  317  that are molded by the mold feature  214   b  and  217  of the second side  202  of the mold. 
     Optical ferrules as described herein may have complex shapes including holes that extend through the ferrule, such as socket  313 . The surface of an optical ferrule includes the surface portions within the holes, e.g., the surface  390  includes the surface within the socket  313 . 
     The parting lines of the mold are the locations of edges of the mold where the first and second sides of the mold come together. During the molding process, parting line artifacts are formed on the surface of the molded part at locations where the parting lines of the two sides of the mold are in contact with the material being molded. Referring again to  FIGS.  2 A and  2 B , a first parting line occurs where the edge of surface  231   a  of the first mold side  201  contacts surface  231   b  of the second mold side  202 . This parting line continues where the edge of surface  214   a  contacts surface  214   b . A secondary parting line occurs where the edge of surface  232   a  of the first side  201  contacts surface  231   b  of the second side  202 . The first parting line extends around a perimeter of the mold, separating the mold halves, and is referred to as the perimeter parting line. A two part mold as shown in  FIGS.  2 A and  2 B  has one perimeter parting line and may have one or more secondary parting lines disposed within the perimeter parting line. 
     The parting line between surfaces  231   a  and  231   b  forms a parting line artifact  331  around a perimeter of the optical ferrule  300 . A second parting line artifact  332  is formed between the surface  232   a  of the shut off plug and surface  231   b . In this example, the second parting line artifact  332  is disposed within the perimeter parting line artifact  331 . 
     In an as-molded ferrule, each parting line artifact may be a closed shape, however, subsequent processing or damage to the as-molded ferrule can remove portions of the parting line artifact resulting in gaps in the parting line artifact. For example, the as-molded ferrule  300  shown in  FIGS.  3 A and  3 B  and the as-molded ferrule  500  shown in  FIGS.  5 A and  5 B  include a runner  395 ,  595  that provides for the injection of molding material and that is removed in a subsequent processing step after molding. In general, the perimeter parting line artifact encloses the perimeter of the as-molded ferrule  300 ,  500  except at the injection site, commonly called the gate. Removal of the runner  395 ,  595  causes a small gap in the perimeter parting line artifact. One or more parting line artifacts, whether closed or open shapes, divide the surface of the ferrule into the first section of the ferrule surface and the second section of the ferrule surface opposite the first section. 
     Optical ferrules according to various embodiments can include molded features that provide for propagation of light within the ferrule and between the ferrule and a mating ferrule that is aligned with the ferrule. For example, the light affecting elements  305  may comprise lenses or mirrors and may affect one or more of a direction and a divergence of the light propagating in the unitary ferrule  300 . In some embodiments, the second side of the mold  202  includes a feature  217  configured to mold an optical output surface  317 , wherein the light propagating in the optical ferrule  300  exits the optical ferrule  300  after being transmitted by the optical output surface  317 . In some embodiments, the one or more surfaces that form the second alignment feature  314  are coated with an optical antireflection coating. 
     The second alignment feature  314  can be a planar surface as shown in  FIGS.  3 B and  3 D  or may include multiple planar surface segments  524  as shown in  FIG.  5 E . However, the second alignment feature need not be planar and may comprise any surface that allows the ferrule  300  to slide relative to and in contact with a compatible mating surface of a mating ferrule. 
     In hermaphroditic ferrule embodiments illustrated herein, the ferrule and the mating ferrule include both male and female components and are substantially identical. However, it is not necessary for the ferrule and the mating ferrule to be identical or hermaphroditic. For example, in some embodiments the second alignment feature of the ferrule may be a convex surface that is configured to slide against a concave surface of a mating connector. 
     The first alignment features of the ferrule  300  include a pin  312  disposed at a mating edge of the ferrule  300 , e.g., extending from the center of the mating edge, wherein the pin  312  is configured to engage a mating socket of a mating ferrule. In some embodiments, the pin  312  can be configured to control translation of the ferrule along both the first lateral axis  121  and the second lateral axis  122 . In other embodiments, a central recess between the mating socket and the pin limits contact between the pin and mating socket to the lateral surfaces of the pin and mating socket. In some embodiments, the central recess provides sufficient clearance between the pin  312  and its mating socket such that the forward stop features  311 , rather than pin  312 , control translation along the first lateral axis  121 . The pin  312  shown in  FIGS.  3 A through  3 D  includes a rounded leading edge, however, in some embodiments the pin may be square, tapered, or angled and the socket of the ferrule and a mating ferrule may have a complementary square, tapered, or angled shape. 
     In some embodiments, the first side of the mold  201  may include a mold feature  218  configured to form a spade portion  318  at a mating end of ferrule  300 . The spade  318  may be configured to facilitate mating of the optical ferrule  300  to a mating optical ferrule with sufficient clearance such that the spade  318  does not significantly control mechanical degrees of freedom when the optical ferrule  300  is mated with a mating ferrule. In some embodiments, as shown in  FIGS.  3 A through  3 D , the pin  312  extends from the spade  318 . Sufficient clearance can also be provided by mold features  213   a ,  212  to allow for flash at the edges of features  313   a ,  312  configured to receive a pin and a socket of a mating ferrule, respectively. In some embodiments, the mating end of the spade may not include a pin (e.g., see  FIGS.  5 A through  5 D ). 
       FIGS.  4 A and  4 B  illustrate first and second sides  401 ,  402  of a mold according to some embodiments.  FIGS.  5 A through  5 D  show first and second sides of a unitary optical ferrule  500  made using the mold of  FIGS.  4 A and  4 B . The first mold side  401  includes first mold features  403 ,  405 ,  411 ,  412 ,  413  and the second mold side  402  includes second mold feature  414 . Mold features  403  are configured to mold elements  503 , e.g. v-, u-, or y-grooves, of the optical ferrule  500  which receive and secure an optical waveguide. Mold features  405  are configured to mold one or more elements  505  of the optical ferrule  500  that affect characteristics of light from the optical waveguide while propagating the light within the unitary ferrule  500 . For example, the light affecting elements  505  may comprise lenses or mirrors and may affect one or more of a direction and a divergence of the light propagating in the unitary ferrule  500 . Although optical ferrule  500  includes multiple receiving and securing elements  503  and multiple light affecting elements  505 , some unitary optical ferrules can include a single receiving and securing element  503  and a single light affecting element  505 . 
     The first mold side  401  includes mold features  411 ,  412 ,  413  configured to mold first alignment features  511 ,  512 ,  513  of the unitary ferrule  500 . One or more mold features  411  are configured to mold one or more alignment features  511  in the ferrule  500  that, when the ferrule  500  is mated with a mating ferrule (not shown), control translation of the ferrule  500  along a first lateral axis  121 . In the embodiment shown in  FIGS.  5 A through  5 D , the features  511  comprise forward stops that, when engaged with forward stops of a mating ferrule, restrict further forward motion along the first lateral axis  121 . The forward stops  511  also control rotation of the ferrule  500  around the thickness axis  123 . 
     One or more mold features  412 ,  413  are configured to mold one or more alignment features  512 ,  513  in the ferrule  500  that control translation of the ferrule  500  along the second lateral axis  122 . In the embodiment of  FIGS.  5 A through  5 D , the optical ferrule  500  includes side arms  512  having contact elements  513 . After the ferrule  500  mates with a mating ferrule, the contact elements  513  of each arm  512  make contact with a side of the mating ferrule. Flexibility in the arms  512  can allow for substantial manufacturing tolerances. When mated with a mating ferrule, the contact elements  513  and side arms  512  control translation of the optical ferrule along the second lateral axis  122  and may also control rotation of the optical ferrule  500  around the thickness axis  123 . Side arms  512  are flexible, thus the side arms  512  and lateral stops  513  limit movement along the second lateral axis  122  but allow some lateral movement of the ferrule. Flexible side arms  512  facilitate alignment of the light affecting elements  505  of the ferrule  500  and the light affecting elements of the mating ferrule. In this example, in equilibrium, the forces created by the flexing of the four arms of the ferrule  500  and the mating ferrule balance to align the ferrules relative to each other. In some embodiments, the ends of the arms provide forward stops that control translation along the first lateral axis  121 . 
     The material forming the compliant features and/or the geometry of the compliant features can be selected to provide a desired alignment force between ferrules. For example, the alignment force provided by the compliant features can be increased or decreased by choosing a material for the compliant features with a higher or lower Young&#39;s modulus, respectively. As another example, in embodiments utilizing flexible arms, the alignment force provided by the flexible arms can be increased or decreased by choosing larger or smaller cross-sectional areas, respectively, for the flexible arms. Useful alignment forces can be obtained by choosing an injection moldable polymer for both a body of the ferrule and the compliant features of the ferrule and by choosing a geometry of the compliant features that can be injection molded along with the body of the ferrule. In this way, for example, a unitary ferrule having compliant features that provide a desired alignment force can be made in an injection molding process. Additional details regarding flexible alignment features are provided in commonly owned and concurrently filed U.S. Patent Application Ser. 62/240,066, having the title “Ferrules, Alignment Frames and Connectors,” and identified by Attorney Docket No. 75767US002 which is incorporated herein by reference. 
     The second mold side  402  includes at least one mold feature  414  configured to mold at least one second alignment feature  514  that, when the ferrule  500  is mated with a mating ferrule, controls translation of the ferrule  500  along the thickness axis  123 , rotation of the ferrule  500  around the first lateral axis  121 , and rotation of the ferrule  300  around the second lateral axis  122 . As shown in  FIG.  5 A through  5 D , the second alignment feature may comprise a planar surface. When making the ferrule  500 , mold sides  401  and  402  are brought together along the parting axis  125 . Surface  414  is preferably normal to the direction of the relative motion of the mold sides (parting axis  125 ), making it insensitive to misalignment of the mold sides. Mold feature  417  is configured to form an optical window  517 , e.g., a recessed optical window, in the planar surface  514 . Optical window  517  may be coated with an antireflective coating. 
     The optical ferrule  500  has a surface  590  that is formed by the first mold side  401  and the second mold side  402 . The surface  590  can be divided into a first section  591  that includes features  503 ,  505 ,  511 ,  512 ,  513  which are formed by the first mold side  401  and a second section  592  that includes features  514  that is formed by the second mold side  402 . 
     Referring again to  FIGS.  4 A- 4 B , a parting line occurs where the edge of surface  431   a  of the first mold side  401  contacts surface  431   b  of the second mold side  402 . The parting line extends around a perimeter of the mold, separating the mold sides. 
     The parting line between surfaces  431   a  and  431   b  forms parting line artifact  531  that extends around a perimeter of the as-molded optical ferrule  500 . The parting line artifact  531  divides the surface  590  of the ferrule  500  into the first section  591  and the second section  592  opposite the first section  591 . The first section  591  includes the receiving and securing elements  503 , the light affecting elements  505 , and one or more first alignment features  511 ,  512 ,  513 . After the ferrule  500  is mated with a mating ferrule, the first alignment features  511 ,  512 ,  513  control translation of the ferrule along the first lateral axis  121 , translation of the ferrule along the second lateral axis  122 , and rotation of the ferrule  500  around the thickness axis  123 . 
     The second section  592  of the surface  590  of the optical ferrule  500  includes at least one second alignment feature  514 . After the ferrule  500  is mated with a mating ferrule, the second alignment feature  514 , which may be a planar surface as shown in  FIG.  5 B , controls translation of the ferrule along the thickness axis  123 , rotation of the ferrule  500  around the first lateral axis  121 , and rotation of the ferrule  500  around the second lateral axis  122 . Mold feature  417  is configured to form an optical window  517 , e.g., a recessed optical window, in the planar surface  514 . 
     In some embodiments, a mold feature  418  is configured to mold a spade  518  of the optical ferrule  500 . The spade  518  may be configured to facilitate mating of the optical ferrule  500  to a mating optical ferrule with sufficient clearance such that the spade  518  does not significantly control mechanical degrees of freedom when the optical ferrule  500  is mated with a mating ferrule. Sufficient clearance can be provided by features  419  in the second side  402  of the mold for the spade of a mating ferrule, allowing for flash at the edges of the spade. 
     An alternative to a planar surface  314 ,  514  illustrated in  FIGS.  3 B and  5 B  is the use channels, bumps and/or rails that provide multiple planar surfaces that mate against a similar surface or a single planar surface of a mating ferrule. The multiple planar surfaces may be multiple co-planar surfaces or multiple parallel surfaces. The total surface area of the planar surface regions is large enough to accommodate any mating forces between ferrules.  FIG.  4 C  illustrates the second side  422  of a mold having a surface  415  that includes mold features  424  configured to mold a surface  515  with multiple channels  524  of the optical ferrule  501  as shown in  FIG.  5 E . The lands of the channels provide multiple planar surfaces  524   a . In various embodiments, the channels  524  may be disposed on one side or both sides of the optical output window  517 . The channels  524  may be substantially parallel to the edges of the optical output window  517  and/or may be disposed at an angle to the optical output window  517 . The flush mating of the planar surfaces  524   a  with a mating ferrule determines three degrees of freedom: translation along the thickness axis  123 , rotation around the first lateral axis  121 , and rotation around the second lateral axis  122 . The three remaining degrees of freedom: translation along the first lateral axis  121 , translation along the second lateral axis  122 , and rotation around the thickness axis  123  are all determined by mating features in the first side of the mold, which also contains the features for molding the optical elements. 
       FIGS.  6 A and  6 B  illustrate first and second sides  601 ,  602  of a mold according to some embodiments.  FIGS.  7 A and  7 B  show first and second sides of a unitary optical ferrule  700  made using the mold of  FIGS.  6 A and  6 B . The first mold side  601  includes first mold features  603 ,  605 ,  612  and the second mold side  602  includes second mold feature  614 . Mold features  603  are configured to mold elements  703 , e.g. grooves, of the optical ferrule  700  which receive and secure an optical waveguide. Mold features  605  are configured to mold one or more elements  705  of the optical ferrule  700  that affect characteristics of light from the optical waveguide while propagating the light within the unitary ferrule  700 . For example, the light affecting elements  705  may comprise lenses or mirrors and/or may affect one or more of a direction and a divergence of the light propagating in the unitary ferrule  700 . Although optical ferrule  700  includes multiple receiving and securing elements  703  and multiple light affecting elements  705 , some unitary optical ferrules can include a single receiving and securing element and a single light affecting element. 
     The first mold side  601  includes mold features  612 ,  613  that are configured to mold first alignment features  712 ,  713  of the unitary optical ferrule  700 . When the ferrule  700  is mated with a mating ferrule (not shown), the first alignment features  712 ,  713  control translation of the ferrule  700  along the first lateral axis  121 , translation of the ferrule along the second lateral axis  122 , and rotation of the ferrule  700  around the thickness axis  123 . Alignment features  712 ,  713  in the ferrule  700  comprise a pointed pin  712  and a pointed socked  713 . Pin  712  is configured to fit into a compatible socket of a mating ferrule, e.g. a socket similar in shape to socket  713 . Socket  713  is configured to receive a compatible pin of a mating ferrule, e.g. a pin similar in shape to pin  712 . 
     The second mold side  602  includes at least one mold feature  614  configured to mold a second alignment feature  714  that, when the ferrule  700  is mated with a mating ferrule, controls translation of the ferrule  700  along the thickness axis  123 , rotation of the ferrule  700  around the first lateral axis  121 , and rotation of the ferrule  700  around the second lateral axis  122 . As shown in  FIG.  7 B , the second alignment feature  714  may comprise a planar surface. When making the ferrule  700 , mold sides  601  and  602  are brought together along the parting axis  125 . Surface  614  is preferably normal to the direction of the relative motion of the mold sides, making it insensitive to misalignment of the mold sides. Mold feature  617  is configured to form an optical window  717 , e.g., a recessed optical window, in the planar surface  714 . Optical window  717  may be coated with an antireflective coating. 
     The optical ferrule  700  has a surface  790  that is formed by the first mold side  601  and the second mold side  602 . The surface  790  can be divided into a first section  791  that includes features  703 ,  705 ,  712 ,  713  which are formed by the first mold side  601  and a second section  792  that includes feature  714  that is formed by the second mold side  602 . 
     Referring again to  FIGS.  6 A and  6 B , a parting line occurs where the edge of surface  631   a  of the first mold side  601  contacts surface  631   b  of the second mold side  602 . The parting line where the edge of surface  631   a  of the first mold side  601  contacts surface  631   b  of the second mold side  602  extends around a perimeter of the mold, separating the mold halves. 
     Referring now to  FIGS.  6 A and  6 B  and  FIGS.  7 A and  7 B , the parting line between surfaces  631   a  and  631   b  forms parting line artifact  731 , shown in more detail in inset  FIG.  7 C , that extends substantially around a perimeter of the optical ferrule  700 . The parting line artifact  731  divides the surface  790  of the ferrule  700  into a first section  791  and the second section  792  opposite the first section  791 . The first section  791  includes the receiving and securing elements,  703 , the light affecting elements  705 , and one or more first alignment features  712 ,  713 . After the optical ferrule is mated with a mating optical ferrule, the first alignment features  712 ,  713  control three degrees of mechanical freedom—translation of the optical ferrule along the first lateral axis  121 , translation of the optical ferrule along the second lateral axis  122 , and rotation of the optical ferrule around the thickness axis  123 . 
     The second section  792  of the surface  790  of the optical ferrule  700  includes at least one second alignment feature  714 . After the ferrule  700  is mated with a mating ferrule, the second alignment feature  714 , which may be a planar surface as shown in  FIG.  7 B , controls three degrees of mechanical freedom: translation of the ferrule  700  along the thickness axis  123 , rotation of the ferrule  700  around the first lateral axis  121 , and rotation of the ferrule  500  around the second lateral axis  122 . 
     In the examples provided above, when the ferrule is mated with a mating ferrule, the bottom surfaces of the ferrules (features  314  of  FIG.  3 B,  514    of  FIG.  5 B,  515    of  FIG.  5 E, and  714    of  FIG.  7 B ) slide and are pressed against each other ensuring that the ferrule  300 ,  500 ,  501 ,  700  and the mating ferrule are parallel and determining the distance along the thickness axis  123  between the receiving and securing elements  303 ,  503 ,  703  (e.g., v-grooves) and the light affecting elements  305 ,  505 ,  705  (e.g., mirror lenses) of the ferrule  300 ,  500 ,  501 ,  700  and the mating ferrule. Because the surface (or multiple surfaces)  314 ,  514 ,  515 ,  714  is/are formed normal to the axis  125  of relative motion of the two sides of the mold, it has no critical dependence on the alignment of the first and second sides of the mold along the first lateral axis  121  and the second lateral axis  122 . As previously discussed, surface  314 ,  514 ,  515 ,  714  may include an optical window where the light beams exit the ferrule. The window is made large enough to accommodate any misalignment in the first and second sides of the mold. 
     As illustrated by  FIGS.  8 A- 10   , in some embodiments, the mold may include features configured to form multiple parallel planar surfaces on the second section of the optical ferrule. During mating, each planar surface provides a sliding surface that slides on a mating surface of a mating ferrule. When mated, the multiple planar surfaces control translation of the optical ferrule along the thickness axis  123 , rotation around the first lateral axis  121 , and rotation around the second lateral axis  122 . In some embodiments, one or more of the planar surfaces may be textured. In some embodiments, the sliding surface may include grooves wherein multiple coplanar surfaces are formed by the lands between the grooves. 
       FIGS.  8 A and  8 B  illustrate first and second sides  801 ,  802  respectively, of a mold, according to some embodiments.  FIGS.  9 A and  9 B  show a unitary optical ferrule  900  made using the mold of  FIGS.  8 A and  8 B . The first mold side  801  includes first mold features  803 ,  805 ,  811 ,  812 ,  813  and the second mold side  802  includes second mold features  814 ,  815   b  and  817 . Mold features  803  of mold side  801  are configured to mold one or more elements  903 , e.g., grooves, of the optical ferrule  900  configured for receiving and securing an optical waveguide. Mold features  805  of mold side  801  are configured to mold one or more elements  905  of the optical ferrule  900  configured for affecting characteristics of light from the optical waveguide while propagating the light within the optical ferrule  900 . Although optical ferrule  900  includes multiple receiving and securing elements  903  and multiple light affecting elements  905 , some unitary optical ferrules can include a single receiving and securing element  903  and a single light affecting element  905 . 
     The first mold side  801  includes mold features  811 ,  812 ,  813  configured to mold one or more first alignment features  911 ,  912 ,  913 . When mated with a mating optical ferrule (not shown), alignment features  911  of the optical ferrule  900  control translation of the ferrule  900  along a first lateral axis  121 , e.g., the first lateral axis. Features  911  shown in the example optical ferrule  900  of in  FIGS.  9 A and  9 B  are forward stops that engage with forward stops of a mating ferrule to set the mated distance between light affecting elements of the optical ferrule and light affecting elements of the mating ferrule. The forward stops  911 , when engaged with forward stops of the mating ferrule, also control rotation of the optical ferrule  900  around the thickness axis  123 . The forward stops  911  are formed by the first side  801  of the mold. 
     Mold features  812 ,  813  are configured to mold alignment features  912 ,  913  in the optical ferrule  900 . In the example ferrule shown in  FIGS.  9 A and  9 B , alignment feature  912  is a pin that fits into a compatible socket of a mating ferrule. Alignment feature  913  is a socket. A portion  913   a  of the socket is molded by mold feature  813   a  and is configured to receive a compatible pin of the mating ferrule. The pin and socket  912 ,  913  control translation of the optical ferrule  900  along the second lateral axis  122  and may also control rotation of the optical ferrule around the thickness axis  123 . Feature  912  may be designed such that only the sides of the pin  912  can come into contact with the mating socket, providing a lateral stop on either side of the pin  912  and thereby controlling translation along the second lateral axis  122 . The pin  912  is designed to be slightly narrower that the socket  913  to allow for manufacturing tolerances. Optionally, compliant features (not shown) could be designed into the pin and/or socket to allow for manufacturing tolerances. In such cases, the pin or the socket, or both, can be fitted with compliant (e.g. elastic) side features that center the pin in the socket. 
     The second mold side  802  includes mold features  814   b  and  815   b  configured to mold parallel planar surfaces  914   b  and  915   b  as second alignment features. When the ferrule  900  is mated with a mating ferrule, the second alignment features  914   a ,  914   b  control translation of the ferrule  900  along the thickness axis  123 , rotation of the ferrule  900  around the first lateral axis  121 , and rotation of the ferrule  900  around the second lateral axis  122 . In the example ferrule  900  shown in  FIGS.  9 A and  9 B , alignment features  914   b  and  915   b  are parallel planar surfaces that, when the optical ferrule  900  is mated with a mating ferrule, control three degrees of mechanical freedom of the optical ferrule  900 . When making the ferrule  900 , mold sides  801  and  802  are brought together through relative motion of the mold sides  801 ,  802  along the parting axis  125 . Surfaces  814   a ,  814   b , and  815   b  are preferably normal to the direction of relative motion of the first and second mold sides (along parting axis  125 ), and being planar, are insensitive to lateral misalignment of the mold sides. 
     The surface  990  of optical ferrule  900  is formed by the first mold side  801  and the second mold side  802 . The complete surface  990  can be divided into a first section  991  which is molded by the first mold side  801  and a second section  992  opposite the first section  991  that is molded by the second mold side  802 . The first section  991  of the surface  990  of the ferrule  900  includes those features  903 ,  905 ,  911 ,  912 ,  913  that are molded by mold features  803 ,  805 ,  811 ,  812 ,  813  of the first side  801  of the mold. The second section  992  of the surface  990  of the ferrule  900  includes the parallel planar surfaces  914   b ,  915   b  and optical output window  917  that are molded by the mold features  814   b ,  815   b , and  817  of the second side  802  of the mold. 
     A first parting line occurs where the edge of surface  831   a  of the first mold side  801  contacts surface  831   b  of the second mold side  802 . This parting line continues where the edge of surface  814   a  contacts surface  814   b . A secondary parting line occurs where the edge of surface  832   a  of the first side  801  contacts surface  831   b  of the second side  802 . The first parting line extends around a perimeter of the mold, separating the mold halves, and is referred to as the perimeter parting line. A two part mold as shown in  FIGS.  8 A and  8 B  has one perimeter parting line and may have one or more secondary parting lines disposed within the perimeter parting line. 
     The parting line between surfaces  831   a  and  831   b  forms a parting line artifact  931  around a perimeter of the optical ferrule  900 . A second parting line artifact  932  is formed between the surface  832   a  of the shut off plug  813  and surface  831   b . In this example, the second parting line artifact  932  is disposed within the perimeter parting line artifact  931 . 
     The as-molded ferrule  900  shown in  FIGS.  9 A and  9 B  includes a runner  995  that provides for the injection of molding material and that is removed in a subsequent processing step after molding.  FIG.  10    provides a cross sectional view of the ferrule  900  mated with a mating ferrule  901 . 
     In some embodiments, as illustrated by  FIGS.  11  through  12   , but also applicable to other molds and ferrules described herein, mold features provide reference planes from which the angular relationships between various surfaces of a ferrule created using the mold can be determined. 
       FIGS.  11 A through  11 C  illustrate first and second sides  1101 ,  1102  of a mold according to some embodiments in which alignment features in addition to the planar mating surface are formed by the second mold side.  FIG.  11 A  provides a perspective view of a first mold side  1101 ;  FIG.  11 B  provides a perspective view of a second mold side  1102 ; and  FIG.  11 C  is a more detailed perspective view of the first mold side  1101 .  FIGS.  12 A through  12 E  show a unitary optical ferrule  1200  made using the mold of  FIGS.  11 A through  11 C .  FIG.  12 A  is a perspective view of a first side  1201  of the ferrule  1200 ;  FIG.  12 B  is a perspective view of the second side  1202  of the ferrule  1200 ;  FIG.  12 C  is a more detailed view of the first ferrule side  1201 ;  FIG.  12 D  is a cross sectional view of the ferrule  1200  mated with a mating ferrule  1250 ;  FIG.  12 E  is another perspective view of the first side  1201  of the ferrule  1200 . 
     The first mold side  1101  includes first mold features  1103 ,  1105 ,  1112  and the second mold side  1102  includes second mold features  1112 ,  1113 ,  1114  and  1117 . Mold features  1103  of mold side  1101  are configured to mold one or more elements  1203 , e.g., grooves, U-shaped, V-shaped, or Y-shaped grooves, of the optical ferrule  1200  configured for receiving and securing an optical waveguide. Mold features  1105  are configured to mold one or more light affecting elements  1205  of the optical ferrule  1200  configured for affecting characteristics of light from the optical waveguide while propagating the light within the optical ferrule  1200 . Mold features  1105  include mold features  1105   a ,  1106 ,  1107 ,  1105   b . Mold feature  1105   a  is configured to mold ferrule light redirecting feature  1205   a . The ferrule light redirecting feature  1205   a  includes a curved lens  1206  and a planar surface  1207  disposed proximate to and/or at least partially surrounding the lens  1206 . Mold features  1106  and  1107 , respectively, are configured to mold the curved lens  1206  and a planar surface  1207 . Mold feature  1105   b  is configured to mold ferrule feature  1205   b  which is an intermediate surface, e.g., a planar surface, disposed between the receiving element  1203  and light redirecting feature  1205   a . Optical ferrule  1200  includes multiple receiving and securing elements  1203  and multiple light affecting elements  1205 , however, some unitary optical ferrules can include a single receiving and securing element and a single light affecting element with an intermediate surface disposed therebetween. 
     Mold side  1101  also includes mold features  1111  configured to mold alignment feature  1211 . Alignment feature  1211  of the optical ferrule  1200  is configured to control translation of the ferrule  1200  along a first lateral axis  121 . 
     The second mold side  1102  includes mold features  1111 ,  1112 ,  1113 ,  1114 ,  1117  configured to mold ferrule features  1211 ,  1212 ,  1213 ,  1214 ,  1217 . When mated with a mating optical ferrule (not shown), alignment features  1211  of the optical ferrule  1200  control translation of the ferrule  1200  along a first lateral axis  121 . Features  1211  shown in the example optical ferrule  1200  of in  FIGS.  12 A and  12 B  are forward stops that engage with forward stops of a mating ferrule to set the mated distance between light affecting elements of the optical ferrule and light affecting elements of the mating ferrule. The forward stops  1211 , when engaged with forward stops of the mating ferrule, may also control rotation of the optical ferrule  1200  around the thickness axis  123 . 
     Mold features  1112 ,  1113  are configured to mold alignment features  1212 ,  1213  in the optical ferrule  1200 . Mold side  1101  includes mold feature  1112   a  comprising spaced apart mold feature portions  1112   a - 1  and  1112   a - 2 . Mold side  1102  includes mold feature  1112   b  that includes spaced apart mold feature portions  1112   b - 1  and  1112   b - 2 . In the example ferrule  1200  shown in  FIGS.  12 A and  12 B , alignment feature  1212  is a pin that fits into a compatible socket of a mating ferrule. Alignment feature  1213  is a socket that receives a pin of the mating ferrule. The pin  1212  includes spaced apart portions  1212   a  and  1212   b . The pin  1212  and socket  1213  control translation of the optical ferrule  1200  along the second lateral axis  122  and may also control rotation of the optical ferrule  1200  around the thickness axis  123 . Pin  1212  may be designed such that only the sides of the pin  1212  can come into contact with the mating socket, providing a lateral stop on either side of the pin  1212  and thereby controlling translation along the second lateral axis  122 . The pin  1212  is designed to be slightly narrower that the socket  1213  to allow for manufacturing tolerances. Optionally, compliant features (not shown) could be designed into the pin and/or socket to allow for manufacturing tolerances. In some embodiments, the compliant features may provide flexible alignment. The pin or the socket, or both, can be fitted with compliant side features that facilitate centering the pin in the socket. 
     Mold feature  1117  is configured to mold the planar mating surface  1217  of the ferrule  1200 . The planar mating surface  1217  controls translation of the ferrule  1200  along the thickness axis  123  and/or rotation of the ferrule along the first and second lateral axes  121 ,  122 . Mold feature  1114  is configured to mold an optical output window  1214  in the planar mating surface  1217 . 
     Optical ferrules and the molds used to make the optical ferrules according to various embodiments, including those illustrated in  FIGS.  1 - 12    above, involve molded features, e.g., plastic molded features, configured to provide for propagation of light within the ferrule and between the ferrule and a mating ferrule that is aligned with the ferrule. For example, the light affecting elements may comprise lenses, e.g., curved lenses, configured to redirect light propagating in the ferrule. As previously described, the optical ferrules can include a planar mating surface having optical output window that is transparent to the propagating light, wherein the light propagating in the optical ferrule exits the optical ferrule after being transmitted by the optical output window. 
     The angular relationship of the mold features are controlled so that the resulting molded features of the ferrule are controlled to specified tolerances to allow for propagation of light within the ferrule between the waveguide, the light affecting element, and the optical output window. As best seen in FIGS.  11 C and  12 C, each light redirecting element  1205  may comprise a curved lens  1206  and at least one planar surface  1207  that may be proximate to and/or may partially or completely surround the lens  1206 . The planar surface  1207  can be used as a first reference plane which sets the positional relationship of lens  1206  with other features of the ferrule  1200 . For example the first reference surface  1207  is disposed at an angle with respect to a second reference surface of the optical ferrule, thus setting the angle of the lens relative to a feature of the receiving element  1203  and/or the longitudinal axis of a waveguide received by the receiving element  1203 . In some embodiments, the mold features can be configured such that the angle between the first reference surface  1207  and the second reference surface is controlled to have a variation less than +/−3 degrees, less than +/−0.3 degrees, less than +/−0.03 degrees, less than +/−0.003 degrees, or even less than +/−0.0003 degrees. Although the lens  1106 ,  1206  and first reference plane  1107 ,  1207  mold and ferrule features are best seen in  FIGS.  11 C and  12 C , it will be appreciated that similar features may be employed by any of the light affecting elements of molds and/or ferrules discussed herein. The angular relationships between the first reference plane and one or more second reference planes as discussed herein can apply to any of the mold and/or ferrule embodiments. 
     In some embodiments, the receiving elements may be a grooves, e.g., V-shaped, U-shaped, or Y-shaped grooves, and the second reference surface may be the bottoms of the grooves. In some embodiments, e.g., as best illustrated by  FIGS.  11  and  12   , the light affecting element  1205  includes an intermediate region  1205   b  extending between the receiving element  1203  and the light redirecting feature  1205   a . The intermediate region  1205   b  comprises the second reference surface. In some implementations, the entire intermediate region  1205   b  may be a planar surface that provides the second reference surface. The second reference surface of the intermediate region  1205   b  may be substantially parallel to the bottom of the receiving element groove. In some embodiments, a planar surface, e.g., planar mating surface  1217 , is disposed on the second side  1202  of the optical ferrule  1200  opposite the first side  1201  of the ferrule which includes the receiving  1203  and light affecting elements  1205 . The planar surface  1217  on the second side of the ferrule may be or comprise the second reference surface. For example, in some implementations, the second reference surface may be the planar mating surface and/or may be the optical output window  1214  or other feature. The optical output window  1214  is transparent to light from the waveguide. In some embodiments, all or portions of the planar mating surface e.g., portions on either side of the optical window  1214 , may be configured to be optically transparent to light. Optical transparency of the planar surface  1217  (or portions thereof) facilitate the use of interferometric analysis to determine angular relationships between the second reference surface of the planar mating surface, the receiving element, the intermediate portion, and/or the first reference surface of the light redirecting feature. The planar mating surface mold feature  1117  may be formed using any technique that provides optical transparency, e.g., grinding, polishing, diamond milling, etc. 
     In some embodiments, one or more fiducials may be made in the mold side (and may be molded into the ferrule) wherein the fiducials correspond to one or more ferrule features. For example, a mold side may be fabricated by one or more tools and each fiducial may be a divot (or other feature) that indicates a location of the tool used form a mold feature. 
     One fiducial may correspond to a plurality of ferrule features or one fiducial may correspond to a single ferrule feature. For example, in implementations that include multiple light affecting elements, multiple fiducials may be used wherein each of the fiducials corresponds to one of the light affecting elements. In some embodiments, as shown in  FIGS.  12 C and  12 E , two or more fiducials  1221 ,  1222  may correspond to a light redirecting feature  1205   a , e.g., each light redirecting feature  1205   a  may be disposed between two fiducials  1221 ,  1222 . 
     According to some implementations, at least one fiducial may correspond to at least a single receiving element. In implementations that include multiple receiving elements, multiple fiducials may be used, wherein each of the fiducials corresponds to one of the receiving elements. For example, as shown in  FIGS.  12 C and  12 E , two or more fiducials  1223 ,  1224  may correspond to one of the receiving elements  1203 , e.g., each receiving element  1203  may be disposed between two fiducials  1223 ,  1224 . Fiducials that correspond to one feature (or type of feature) may have the same shape or may differ in shape from fiducials that correspond to another feature (or type of feature). 
     Additional information regarding ferrules that may be formed by approaches described herein and alignment frames and connectors that may be used with ferrules formed by the disclosed approaches is provided in the following commonly owned and concurrently filed U.S. patent applications which are incorporated herein by reference: U.S. Patent Application Ser. 62/239,998, having the title “Connector with Latching Mechanism” and identified by Attorney Docket Number 76663US002; U.S. Patent Application Ser. 62/240,069, having the title “Optical Ferrules” and identified by Attorney Docket Number 76982US002; U.S. Patent Application Ser. 62/240,066, having the title “Ferrules, Alignment Frames and Connectors,” and identified by Attorney Docket Number 75767US002; U.S. Patent Application Ser. 62/240,008, having the title “Optical Cable Assembly with Retainer,” identified by Attorney Docket Number 76662US002; U.S. Patent Application Ser. 62/240,000, having the title “Dust Mitigating Optical Connector,” identified by Attorney Docket Number 76664US002; U.S. Patent Application Ser. 62/240,009, having the title “Optical Waveguide Registration Feature,” identified by Attorney Docket Number 76661US002; U.S. Patent Application Ser. 62/240,010, having the title “Optical Coupling Device with Waveguide Assisted Registration,” identified by Attorney Docket Number 76660US002; U.S. Patent Application 62/240,002, having the title “Optical Ferrules with Waveguide Inaccessible Space,” identified by Attorney Docket Number 76778US002; U.S. Patent Application 62/240,003 having the title “Configurable Modular Connectors,” identified by Attorney Docket Number 76907US002; and U.S. Patent Application 62/240,005, having the title “Hybrid Connectors,” identified by Attorney Docket Number 76908US002. 
     Items described in this disclosure include:
 
Item 1. A molded unitary optical ferrule comprising:
 
     one or more parting line artifacts, the one or more parting line artifacts including a parting line artifact extending substantially around an external perimeter of the unitary ferrule, the parting line artifacts dividing a surface of the optical ferrule along a thickness axis into a first section and an opposing second section, wherein
         the first section of the surface includes:
           one or more elements configured for receiving and securing a optical waveguide;   one or more elements configured for affecting one or more characteristics of light from the optical waveguide while propagating the light within the unitary ferrule; and   one or more first alignment features that, when the ferrule is mated with a mating ferrule, control translation of the ferrule along a first lateral axis orthogonal to the thickness axis, translation of the ferrule along a second lateral axis orthogonal to both the thickness axis and the first lateral axis, and rotation of the ferrule around the thickness axis; and   
           the second section includes at least one second alignment feature that, when the ferrule is mated with a mating ferrule, controls translation of the ferrule along the thickness axis, and rotation of the ferrule around the first and second lateral axes.
 
Item 2. The ferrule of item 1, wherein the first lateral axis is a ferrule mating axis.
 
Item 3. The ferrule of any of items 1 through 2, wherein the one or more parting lines comprise one or more additional parting lines within the perimeter parting line.
 
Item 4. The ferrule of any of items 1 through 3, wherein the one or more characteristics of the light propagating within the unitary ferrule include one or more of a direction and divergence of the light.
 
Item 5. The ferrule of any of items 1 through 4 further comprising an output surface, the light propagating within the unitary ferrule exiting the ferrule after being transmitted by the output surface, the output surface disposed in the second section.
 
Item 6. The ferrule of item 5, wherein at least the output surface is coated with an optical antireflection coating.
 
Item 7. The ferrule of any of items 1 through 6, wherein the second alignment feature comprises at least one planar surface.
 
Item 8. The ferrule of item 7, wherein the at least one planar surface is a single planar surface.
 
Item 9. The ferrule of item 7, wherein the at least one planar surface are multiple parallel planar surfaces.
 
Item 10. The ferrule of item 7, wherein the at least one planar surface are multiple coplanar surfaces.
 
Item 11. The ferrule of item 7 wherein, during mating, the at least one planar surface slides on a planar surface of a mating ferrule.
 
Item 12. The ferrule of item 7, wherein the receiving and securing elements and the light affecting elements are disposed on a surface of the ferrule opposite the at least one planar surface.
 
Item 13. The ferrule of any of items 1 through 12, wherein the first alignment features comprise a pin disposed at a mating edge of the ferrule, the pin configured to engage a mating socket of the mating ferrule, the pin configured to control one or more of translation of the ferrule along the second lateral axis and translation of the ferrule along the first lateral axis.
 
Item 14. The ferrule of item 13, wherein the mating socket is formed by a hole through the thickness direction of the ferrule.
 
Item 15. The ferrule of item 13, wherein a leading edge of the pin is rounded.
 
Item 16. The ferrule of item 13, wherein a leading edge of the pin is angular.
 
Item 17. The ferrule of item 13, wherein clearance between a leading edge of the pin and a mating socket limits contact between the pin and socket to lateral surfaces of the pin.
 
Item 18. The ferrule of any of items 1 through 17, further comprising a spade portion at a mating edge of the optical ferrule.
 
Item 19. The ferrule of any of items 1 through 18, wherein the first alignment features includes a first stop disposed at a first side of the ferrule and a second stop disposed at a second side of the ferrule, the first and second stops controlling at least one of translation of the ferrule along the first lateral axis and rotation of the ferrule around the thickness axis.
 
Item 20. The ferrule of item 19, wherein the first alignment features comprise a first flexible arm disposed at a first side of the ferrule and a second flexible arm disposed at a second side of the ferrule, each of the first arm and the second arm including a contact element, each contact element configured to engage a side of a the mating ferrule.
 
Item 21. The ferrule of item 20, wherein engagement of the contact elements with the sides of the mating ferrule controls control translations of the ferrule along the second lateral axis.
 
Item 22. A molded unitary optical ferrule comprising:
       

     one or more parting line artifacts, including a parting line artifact extending substantially around an external perimeter of the unitary ferrule, the parting line artifacts dividing a surface of the optical ferrule along the thickness axis into a first section and an opposing second section; 
     one or more elements configured for receiving and securing an optical waveguide; 
     one or more elements configured for affecting one or more characteristics of light from the optical waveguide while propagating the light within the unitary ferrule; 
     at least one planar surface configured to make contact with a planar mating surface of a mating ferrule during mating of the ferrule; and 
     one or more alignment features that, when the ferrule mates with the mating ferrule, primarily control rotation of the ferrule around a thickness axis, translation of the ferrule along a first lateral axis orthogonal to the thickness axis, and translation of the ferrule along a second lateral axis orthogonal to the thickness axis and to the first lateral axis, wherein the first section of the ferrule contains the one or more elements configured for receiving and securing the optical waveguide, the one or more elements configured for affecting one or more characteristics of light, and the alignment features and the second section of the ferrule includes the planar surface. 
     Item 23. The ferrule of item 22, wherein the at least one planar mating surface comprises a plurality of lands between a plurality of grooves. 
     Item 24. The ferrule of any of items 22 through 23, wherein the at least one planar mating surface comprises multiple planar mating surfaces. 
     Item 25. The ferrule of any of items 22 through 24, wherein the one or more alignment features comprises a socket formed by a hole through the thickness axis of the ferrule. 
     Item 26. A molded unitary optical ferrule comprising: 
     one or more parting line artifacts, including a parting line artifact extending substantially around an external perimeter of the unitary ferrule, the parting line artifacts dividing a surface of the optical ferrule along a thickness axis into a first section and an opposing second section; 
     one or more elements configured for receiving and securing an optical waveguide; 
     one or more elements configured for affecting one or more characteristics of light from the optical waveguide while propagating the light within the unitary ferrule; 
     a sliding surface that, during mating of the ferrule and a mating ferrule, facilitates sliding of the ferrule against a sliding surface of the mating ferrule along a ferrule mating axis, when the ferrule is mated with the mating ferrule, the sliding surface is configured to control rotation of the ferrule around the ferrule mating axis, translation of the ferrule along a thickness axis orthogonal to the ferrule mating axis, and rotation of the ferrule around a lateral axis orthogonal to the ferrule mating axis and the thickness axis; and 
     one or more alignment features that, when the ferrule is mated with the mating ferrule, primarily control translation of the ferrule along the ferrule mating axis, translation of the ferrule along the lateral axis, and rotation of the ferrule around the thickness axis, wherein the first section of the surface includes the receiving and securing elements, the light affecting elements, and the alignment features and the second section of the surface includes the sliding surface. 
     Item 27. The ferrule of item 26, wherein the sliding surface comprises multiple planar surfaces.
 
Item 28. An injection mold comprising:
 
     a first mold side and a second mold side that fit together to define a cavity for molding a unitary optical ferrule, the cavity configured to separate along a parting axis, 
     the unitary optical ferrule being molded with a thickness axis parallel to the parting axis, 
     the first mold side having first mold features configured to mold:
         a plurality of first elements configured for receiving and securing an optical waveguide and for affecting one or more characteristics of light from the optical waveguide while propagating the light within the unitary ferrule; and   one or more first alignment features that, when the ferrule is mated with a mating ferrule, control translation of the ferrule along a first lateral axis orthogonal to the thickness axis, translation of the ferrule along a second lateral axis orthogonal to both the thickness axis and the first lateral axis, and rotation of the ferrule around the thickness axis;       

     the second mold side having second mold features configured to mold one or more second alignment features that, when the ferrule is mated with a mating ferrule, control translation of the ferrule along the thickness axis, and rotation of the ferrule around the first and second lateral axes. 
     Item 29. The injection mold of item 28, wherein the first lateral axis is a mating axis of the optical ferrule.
 
Item 30. The injection mold of any of items 28 through 29, wherein the second mold side includes a feature configured to mold an optical output surface.
 
Item 31. The injection mold of any of items 28 through 30, wherein the one or more second alignment features comprises at least one planar surface.
 
Item 32. The injection mold of item 31, wherein the parting axis is substantially perpendicular to at least one planar surface.
 
Item 33. The injection mold of any of items 28 through 32, wherein the first mold side comprises a unitary mold insert that includes the first mold features.
 
Item 34. The injection mold of any of items 28 through 33, wherein the one or more second alignment features is a single planar surface.
 
Item 35. The injection mold of any of claims  28  through  33 , wherein the one or more second alignment features is a multiple parallel planar surfaces.
 
Item 36. The injection mold of any of claims  28  through  33 , wherein the one or more second alignment features is a multiple coplanar surfaces.
 
Item 37. The injection mold of any of items 28 through 36, wherein the first alignment features comprise a pin disposed at a mating edge of the ferrule, the pin configured to control one or both of translation of the ferrule along the first lateral axis and translation of the ferrule along both the second lateral axis.
 
Item 38. The injection mold of item 37, wherein a leading edge of the pin is rounded.
 
Item 39. The injection mold of item 37, wherein a leading edge of the pin is angular.
 
Item 40. The injection mold of any of items 28 through 39, wherein the first mold side includes a feature configured to mold a spade portion at a mating edge of the optical ferrule.
 
Item 41. The injection mold of any of items 28 through 40, wherein the first alignment features include a first stop disposed at a first side of the ferrule and a second stop disposed at a second side of the ferrule, the first and second stops controlling translation of the ferrule along the first lateral axis.
 
Item 42. An optical ferrule comprising:
 
     one or more receiving elements, each receiving element configured for receiving and securing an optical waveguide; and 
     one or more light affecting elements, each light affecting element comprising:
         a light redirecting feature comprising:
           a curved lens in an optical path of light from the optical waveguide, the receiving element configured to align the waveguide with the lens; and   a planar region at least partially surrounding the lens and comprising a first reference surface for the lens; and   
           an intermediate surface that extends between the receiving element and the light redirecting feature and comprising a second reference surface, wherein the first reference surface is disposed at a predetermined angle with respect to the second reference surface that determines a positional relationship between the lens and the waveguide.
 
Item 43. The optical ferrule of item 42, wherein variation in the angle is controlled to less than +/−3 degrees.
 
Item 44. The optical ferrule of item 42, wherein variation in the angle is controlled to less than +/−0.3 degrees.
 
Item 45. The optical ferrule of item 42, wherein variation in the angle is controlled to less than +/−0.03 degrees.
 
Item 46. The optical ferrule of item 42, wherein variation in the angle is controlled to less than +/−0.003 degrees.
 
Item 47. The optical ferrule of item 42, wherein variation in the angle is controlled to less than +/−0.0003 degrees.
 
Item 48. The optical ferrule of item 42, wherein the intermediate surface is a planar surface.
 
Item 49. The optical ferrule of any of items 42 through 48, wherein the intermediate planar surface is disposed at a known angle with respect to a feature of the receiving element.
 
Item 50. The optical ferrule of any of items 42 through 49, wherein the receiving element is a groove and the receiving element feature is the bottom of the groove.
 
Item 51. The optical ferrule of item 50, wherein the groove is a U or V-shaped groove.
 
Item 52. The optical ferrule of item 50, wherein the intermediate surface is parallel with the feature of the receiving element.
 
Item 53. The optical ferrule of any of items 42 through 52, wherein the receiving elements and the light affecting elements are disposed on a first side of the optical ferrule and further comprising a planar mating surface disposed on a second side of the optical ferrule opposite the first side.
 
Item 54. The optical ferrule of item 53, wherein the planar mating surface is parallel to the feature of the receiving element.
 
Item 55. The optical ferrule of item 54, wherein the receiving element is a groove and the feature is the bottom of the groove.
 
Item 56. The optical ferrule of item 55, wherein the groove is a U or V-shaped groove.
 
Item 57. The optical ferrule of item 55, wherein the groove is a Y-shaped groove.
 
Item 58. The optical ferrule of item 53, wherein the second side further comprises an optical window configured to transmit the light out of the optical ferrule, wherein forward and rear portions of the planar mating surface are disposed on either side of the optical window.
 
Item 59. The optical ferrule of item 58, wherein at least one of the forward and rear regions of the planar mating surface is optically transparent.
 
Item 60. The optical ferrule of any of items 42 through 59, further comprising at least one fiducial corresponding to at least one of the light affecting element and the receiving element.
 
Item 61. The optical ferrule of any of items 42 through 60, further comprising at least a first fiducial corresponding to the light affecting element and at least a second fiducial corresponding to the receiving element.
 
Item 62. The optical ferrule of any of items 42 through 61, wherein the optical ferrule includes a plurality of light affecting elements and a plurality of receiving elements and further comprising at least one fiducial corresponding to at least one of the plurality of light affecting elements.
 
Item 63. The optical ferrule of any of items 42 through 62, wherein the optical ferrule includes a plurality of light affecting elements and a plurality of receiving elements and further comprising at least one fiducial corresponding to at least one of the plurality of receiving elements.
 
Item 64. The optical ferrule of items 42 through 63, wherein the optical ferrule includes a plurality of light affecting elements and a plurality of receiving elements and further comprising one or more fiducials corresponding to each of the plurality of receiving elements and one or more fiducials corresponding to each of the plurality of light affecting elements.
 
Item 65. An optical ferrule comprising:
       

     one or more receiving elements, each receiving element configured for receiving and securing an optical waveguide; and 
     one or more light affecting elements, each light affecting element comprising:
         a light redirecting feature comprising:
           a curved lens in an optical path of light from the optical waveguide, the receiving element configured to align the waveguide with the lens; and   a planar region at least partially surrounding the lens the planar region comprising a first reference surface for the lens,
 
wherein the first reference surface is disposed at an angle with respect to a second reference surface of the optical ferrule that determines a positional relationship between the lens and the waveguide.
 
Item 66. The optical ferrule of item 65, wherein the receiving element comprises a groove and the second reference surface is the bottom of the groove.
 
Item 67. The optical ferrule of item 66, wherein the groove is a V-shaped or U-shaped groove.
 
Item 68. The optical ferrule of item 66, wherein the groove is a Y-shaped groove.
 
Item 69. The optical ferrule of any of claims  65  through  68 , wherein variation in the angle is controlled to less than +/−3 degrees.
 
Item 70. The optical ferrule of any of items 65 through 68, wherein the variation in the angle is controlled to less than +/−0.3 degrees.
 
Item 71. The optical ferrule of any of items 65 through 68, wherein variation in the angle is controlled to less than +/−0.03 degrees.
 
Item 72. The optical ferrule of any of items 65 through 68, wherein variation in the angle is controlled to less than +/−0.003 degrees.
 
Item 73. The optical ferrule of any of items 65 through 68, wherein variation in the angle is controlled to less than +/−0.0003 degrees.
 
Item 74. The optical ferrule of any of items 65 through 73, wherein the light affecting element includes an intermediate surface that extends between the receiving element and the light affecting element and the intermediate surface comprises the second reference surface.
 
Item 75. The optical ferrule of any of items 65 through 74, wherein the receiving elements and the light affecting elements are disposed on a first side of the optical ferrule and further comprising a planar surface disposed on a second side of the optical ferrule opposite the first side and the planar surface comprises the second reference surface.
 
Item 76. The optical ferrule of item 75, wherein the second side further comprises an optical window configured to transmit the light out of the optical ferrule, wherein forward and rear portions of the planar mating surface are disposed on either side of the optical window.
 
Item 77. The optical ferrule of item 75, wherein at least one of the forward and rear regions of the planar mating surface is optically transparent.
 
Item 78. The optical ferrule of any of items 65 through 77, further comprising at least one fiducial corresponding to at least one of the light affecting element and the receiving element.
 
Item 79. The optical ferrule of any of items 65 through 78, further comprising at least a first fiducial corresponding to the light affecting element and at least a second fiducial corresponding to the receiving element.
 
Item 80. The optical ferrule of any of items 65 through 79, wherein the optical ferrule includes a plurality of light affecting elements and a plurality of receiving elements and further comprising at least one fiducial corresponding to at least one of the plurality of light affecting elements.
 
Item 81. The optical ferrule of any of items 65 through 80, wherein the optical ferrule includes a plurality of light affecting elements and a plurality of receiving elements and further comprising at least one fiducial corresponding to at least one of the plurality of receiving elements.
 
Item 82. The optical ferrule of any of items 65 through 81, wherein the optical ferrule includes a plurality of light affecting elements and a plurality of receiving elements and further comprising one or more fiducials corresponding to each of the plurality of receiving elements and one or more fiducials corresponding to each of the plurality of light affecting elements.
 
Item 83. The optical ferrule of any of items 65 through 82, wherein the first reference surface provides a local reference for the lens.
 
Item 84. An injection mold comprising:
   
               

     a first mold side and a second mold side that fit together to define a cavity for molding a unitary optical ferrule, the cavity configured to separate along a parting axis, the unitary optical ferrule being molded with a thickness axis parallel to the parting axis, the first mold side having mold features configured to mold: 
     one or more light affecting elements, each light affecting element comprising: 
     a light redirecting feature comprising: 
     a curved lens in an optical path of light from the optical waveguide, the receiving element configured to align the waveguide with the lens; and 
     a planar region at least partially surrounding the lens and comprising a first reference surface for a position of the lens, 
     wherein the first reference surface is disposed at an angle with respect to a second reference surface of the optical ferrule that determines a positional relationship between the lens and the waveguide.
 
Item 85. The injection mold of item 84, wherein the receiving element comprises a groove and the second reference surface is the bottom of the groove.
 
Item 86. The injection mold of item 85, wherein the groove is a V-shaped or U-shaped groove.
 
Item 87. The injection mold of item 85, wherein the groove is a Y-shaped groove.
 
Item 88. The injection mold of item 84, wherein variation in the angle is controlled to less than +/−3 degrees.
 
Item 89. The injection mold of item 84, wherein the variation in the angle is controlled to less than +/−0.3 degrees.
 
Item 90. The injection mold of item 84, wherein variation in the angle is controlled to less than +/−0.03 degrees.
 
Item 91. The injection mold of item 84, wherein variation in the angle is controlled to less than +/−0.003 degrees.
 
Item 92. The injection mold of item 84, wherein variation in the angle is controlled to less than +/−0.0003 degrees.
 
Item 93. The injection mold of any of items 84 through 92, wherein the light affecting element includes an intermediate surface that extends between the receiving element and the light affecting element and the intermediate surface comprises the second reference surface.
 
Item 94. The injection mold of items 84 through 93, wherein the receiving elements and the light affecting elements are disposed on a first side of the optical ferrule and further comprising a planar surface disposed on a second side of the optical ferrule opposite the first side and the planar surface comprises the second reference surface.
 
Item 95. The injection mold of item 94, wherein the second side further comprises an optical window configured to transmit the light out of the optical ferrule, wherein forward and rear portions of the planar mating surface are disposed on either side of the optical window.
 
Item 96. The injection mold of item 95, wherein at least one of the forward and rear regions of the planar mating surface is optically transparent.
 
Item 97. The injection mold of any of items 84 through 96, wherein the first mold side includes at least one mold feature configured to mold at least one fiducial corresponding to at least one of the light affecting element and the receiving element.
 
Item 98. The injection mold of any of items 84 through 97, wherein the first mold side includes at least one mold feature configured to mold at least a first fiducial corresponding to the light affecting element and at least one mold feature configured to mold at least a second fiducial corresponding to the receiving element.
 
Item 99. The injection mold of any of items 84 through 98, wherein mold features are configured to mold a plurality of light affecting elements, a plurality of receiving elements and at least one fiducial corresponding to at least one of the plurality of light affecting elements.
 
Item 100. The injection mold of any of items 84 through 99, wherein the mold features are configured to mold a plurality of light affecting elements, a plurality of receiving elements and at least one fiducial corresponding to at least one of the plurality of receiving elements.
 
Item 101. The injection mold of any of items 84 through 100, wherein the mold features are configured to mold a plurality of light affecting elements, a plurality of receiving elements, one or more fiducials corresponding to each of the plurality of receiving elements, and one or more fiducials corresponding to each of the plurality of light affecting elements.
 
Item 102. The injection mold of any of items 84 through 101, wherein the first reference surface provides a local reference for the lens.
 
     Unless otherwise indicated, all numbers expressing feature sizes, amounts, and physical properties used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the foregoing specification and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by those skilled in the art utilizing the teachings disclosed herein. The use of numerical ranges by endpoints includes all numbers within that range (e.g. 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5) and any range within that range. 
     Various modifications and alterations of the embodiments discussed above will be apparent to those skilled in the art, and it should be understood that this disclosure is not limited to the illustrative embodiments set forth herein. The reader should assume that features of one disclosed embodiment can also be applied to all other disclosed embodiments unless otherwise indicated. It should also be understood that all U.S. patents, patent applications, patent application publications, and other patent and non-patent documents referred to herein are incorporated by reference, to the extent they do not contradict the foregoing disclosure.