High Precision Optical Fiber Array Connector and Method

An optical fiber array connector in which the tolerance of the diameter of the mask openings are not factors in the overall positioning of the plurality of fibers. The array includes a mask element with rear and forward surfaces and a plurality of openings that communicate through these surfaces. A plurality of optical fibers include fiber ends having substantially truncated conical side surfaces that extend through the openings and engage the portions of the mask openings nearest the mask rear surface. A method includes preparing the fibers to form a conical surface at their distal ends, preparing the openings in the primary mask each with a diameter less than the diameter of the fiber cladding or second layer, inserting the conical fiber ends until the conical surfaces engage the mask opening walls, applying bonding material to the mask forward surface and exposed tips, grinding and polishing the exposed tips and bonding material surface to truncate the cones and expose the fiber core diameters.