Various embodiments of optical fiber designs and fabrication processes for ultra small core fibers (USCF) are disclosed. In some embodiments, the USCF includes a core that is at least partially surrounded by a region comprising first features. The USCF further includes a second region at least partially surrounding the first region. The second region includes second features. In an embodiment, the first features are smaller than the second features, and the second features have a filling fraction greater than about 90 percent. The first features and/or the second features may include air holes. Embodiments of the USCF may provide dispersion tailoring. Embodiments of the USCF may be used with nonlinear optical devices configured to provide, for example, a frequency comb or a supercontinuum.