Focused sterilization and sterilized sub-assemblies for analyte monitoring systems

A method of assembling an analyte sensor for delivery comprising:

• providing a sensor control device including:
• an electronics housing including a shell having a first aperture and a mount secured to the shell to define an interior space, the mount having a second aperture aligned with the first aperture, a circuit board disposed within the interior space of the electronics housing and including a plurality of electronics modules, an analyte sensor including an in vivo portion extending through the second aperture and configured to measure an analyte level in a bodily fluid, an ex vivo portion within the interior space of the electronics housing and including a plurality of electrical contacts coupled with the circuit board, and a neck portion interconnecting the in vivo portion and the ex vivo portion, a sharp hub adapted for engagement with the sensor control device and including a sharp and a mating member, the mating member configured to extend through the first and second aperture and distally from an underside of the mount, and a sensor cap having a first end, a second end, and an inner chamber, wherein the inner chamber receives at least a portion of the in vivo portion of the analyte sensor and wherein the first end is removably coupled to the mating member to seal the inner chamber;
• and
• providing an applicator for delivery of the analyte sensor including:
• a housing including a sensor carrier configured to secure the sensor control device within an interior of the applicator, and an applicator cap removably coupled to the housing to seal the interior of the applicator, wherein the applicator cap mates with an engagement feature on the second end of the sensor cap when applicator cap is coupled to the housing, and wherein the sensor cap detaches from the mating member and remains mated with the applicator cap when applicator cap is removed from the housing.