A consumable fusion block for fusing optical fibers includes non-conducting substrate with at least one flat surface. A pair of electrodes overlay the flat surface of the substrate and are spaced apart on either side of a passline such that each electrode tip end is adjacent the passline. A space between the electrode tips defines an arc region which can be covered to form a semi-enclosed arc region. A method is also provided for manufacturing a plurality of fusion blocks from a single slab of non-conducting material by overlying the non-conducting material with a length of conducting material, bonding the conducting material to the non-conducting material, and cutting the slab into smaller fusion blocks.