Analyte sensors and methods for fabricating analyte sensors

A method for fabricating analyte sensors in a roll-to-roll process, the method comprising:

• providing a roll of a polyester substrate having a first side sputtered with a layer of platinum, wherein the platinum is in direct contact with the polyester substrate;
• patterning the layer of platinum to form working electrodes and reference electrodes;
• forming an insulating dielectric layer over the polyester substrate, wherein the insulating dielectric layer is formed with openings overlying portions of the working electrodes and portions of the reference electrodes;
• punching the polyester substrate to form ribbons, wherein each ribbon is connected to a remaining polyester substrate web by a tab, and wherein each sensor includes one of the working electrodes and one of the reference electrodes;
• and
• after punching the polyester substrate to form ribbons, depositing an enzyme layer over the portions of the working electrodes and coating the working electrodes with a glucose limiting membrane.

A method for fabricating analyte sensors in a roll-to-roll process, the method comprising:

• providing a roll of a polyester substrate having a first side sputtered with a layer of platinum, wherein the platinum is in direct contact with the polyester substrate;
• patterning the layer of platinum to form reference electrodes;
• forming an insulating dielectric layer over the polyester substrate, wherein the insulating dielectric layer is formed with openings lying directly over and defining geometric electrode surface areas of each reference electrode;
• forming a protection layer over the reference electrodes;
• printing silver/silver chloride ink over the protection layer over the geometric electrode surface areas of the reference electrodes;
• after printing the silver/silver chloride ink, punching the polyester substrate to form ribbons, wherein each ribbon is connected to a remaining polyester substrate web by a tab, and wherein each sensor includes one of the working electrodes and one of the reference electrodes;
• depositing an enzyme layer over the working electrodes;
• and
• coating the working electrodes with a glucose limiting membrane.