Patent ID: 8087162

Claim:
A method of manufacturing electrochemical sensors, the method comprising the steps of: forming a plurality of working electrodes on a first region of a first substrate, the working electrodes comprising a material selected from the group consisting of gold, carbon, platinum, ruthenium dioxide, and palladium; forming a plurality of counter electrodes on a second region of the first substrate, the counter electrodes comprising a material selected from the group consisting of silver/silver chloride, gold, carbon, platinum, ruthenium dioxide, and palladium; disposing a spacer layer overlaying the working and counter electrodes, the spacer layer having a thickness of no more than 0.2 mm; removing a portion of the spacer layer to define a portion of a boundary for a sample chamber; disposing analyte-responsive enzyme in at least a portion of the sample chamber; overlaying the first substrate and the spacer layer with a second substrate to form a layered structure; and separating the layered structure into a plurality of electrochemical sensors, each electrochemical sensor comprising: at least one working electrode having a working area of no more than about 0.01 cm 2 , at least one counter electrode, wherein each at least one working electrode is spaced from each at least one counter electrode by 25-1000 micrometers, at least one sample chamber having a volume less than 1 microliter and including a circular recess having at least a portion of the working electrode and a diffusible redox mediator situated in the recess, and first and second lateral extensions from the sensor body flanking the sample chamber region to indicate to a user where the openings for the sample chamber are provided.