The embodiments disclosed herein seek to eliminate substantially all of the voids or air gaps among neighboring fibers within a CFU by wetting a plurality of optical fibers that comprises the CFU with an acrylate prepolymer resin before the plurality of the optical fibers are grouped together tightly. In one embodiment, instead of extruding a first acrylate prepolymer resin to the optical fibers immediately after a first die, the disclosed process wets the optical fibers with a first acrylate prepolymer resin prior to the first die.