Methods of manufacture to optimize performance of transdermal sampling and analysis device

A method of making a transdermal sampling and analysis device adapted to be placed on skin, the method comprising:

• forming a base structure with at least a first electrode and a plurality of channel support structures;
• forming a lid structure configured to be positioned above the at least first electrode, wherein forming the lid structure comprises:
• depositing a conductive material layer on a lid substrate to create a lid conductive material layer;
• and
• patterning the lid conductive material layer to form at least a second electrode;
• and
• attaching the lid structure to the base structure using an adhesive material on surfaces of the plurality of channel support structures,
• wherein attaching the lid structure to the base structure forms a plurality of channels in a reservoir between the plurality of channel support structures,
• wherein the reservoir comprises:
• a circular collection portion configured to collect a biological sample obtained through permeable skin barrier cells, wherein the circular collection portion is substantially parallel to a plane of the skin;
• and
• a sensing chamber portion configured to receive the biological sample from the circular collection portion, wherein the sensing chamber portion surrounds a periphery of the circular collection portion substantially parallel to the plane of the skin, wherein the at least first electrode and the at least second electrode are located proximate to the sensing chamber portion.