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This paper presents the design, fabrication and testing of a novel 1 × 4 mechanical optical switch, whose components are fabricated by precision machining and MEMS technologies. The switch uses two relays as the two actuators whose switching direction is perpendicular to each other by an orthogonal arrangement. We adopt a direct fiber-to-fiber principle that aligns the input fiber directly to four output fibers. This configuration eliminates the use of traditional parts such as collimators, turning mirrors or prisms. In addition, due to the use of a fiber holder, the fiber position errors could be reduced to less than 0.27 µm using the two-stage geometry error reduction principle. We have successfully developed a simple and low-cost switch, which performs like most of the 1 × 4 mechanical optical switches that dominate the optics communications market. The advantages of our switch are a small size (20 × 20 × 25 mm3), low cost, high reliability, and the latching function does not need external force for maintaining the state. The experimental results showed that the insertion losses of the four channels are ch1: 0.68 dB, ch2: 1.49 dB, ch3: 0.71 dB and ch4: 0.97 dB. The switching time is 5 ms, the crosstalk ⩽80 dB. The reliability tests of the insertion loss after 10 000 cycles in four channels yield ch1: 1.67 dB, ch2: 1.63 dB, ch3: 0.75 dB and ch4: 0.98 dB. The size and the cost of our 1 × 4 mechanical optical switch are only about 1/5–1/10 and 1/10 of the series-connect-type and prism-type switches, respectively.