A method of making a multi-fiber assembly with irregular hexagonal array, which includes the steps of forming a plurality of primitives each made of a plurality of fibers, said fibers having cylindrical outer surfaces of same diameter and being arranged in an irregular hexagonal array, said irregular hexagonal array having six sides wherein three alternate sides of said primitive are each composed of n fibers and the other three alternate sides of said primitive 11 are each composed of n−1 fibers; and bringing together said primitives in such a way that sides with n fibers of said primitives are in contact with sides with n−1 fibers of other primitive thereby arranging said fibers at a central portion among said primitives in alignment with one another and therefore preventing said fibers at said central portion from squeezing one another.