Patent ID: 8551308

Claim:
A method of making a plurality of biosensors having first and second electrode elements formed on each of the plurality of biosensors, said plurality of biosensors being produced by: (a) providing a web of base substrate material having a metal conductive layer formed thereon; (b) projecting an image of an electrode pattern onto the metal conductive layer with a laser apparatus, wherein an electrode pattern that corresponds to the image is formed by laser ablation on the web of base substrate material, the electrode pattern comprising first and second electrode elements having first and second respective edges defining a gap there between, the gap having a width and a length, wherein each of the first and second edges are spaced from first and second theoretical lines, respectively, by a distance that varies along the length of the gap, the theoretical lines defining desired shape and placement of the first and second edges, wherein the standard deviation of the each of the distances is less than about 6 μm over the entire length of the gap; (c) moving the web of base substrate material and repeating step (b) a plurality of times to produce a plurality of the electrode patterns at spaced intervals along the web of base substrate material; (d) depositing a reagent on the web of base substrate material and at least partially covering each electrode pattern of the plurality of electrode patterns with the reagent; (e) laminating at least one web of a covering layer or a spacing layer over the web of base substrate material, thereby forming a cover and a sample-receiving chamber for each biosensor; and (f) cutting through the at least one web of a covering layer or a spacing layer and the web of base substrate material to form the plurality of biosensors.