Methods for needle alignment for wearable biosensors

A method of aligning a needle with a pathway in a housing of a wearable sensor device, comprising:

• aligning the needle with a first opening defined in the housing of the wearable sensor device, the housing comprising an upper portion and a lower portion, wherein:
• the upper portion comprises the first opening extending therethrough,
• the lower portion comprises a second opening extending therethrough, and
• the pathway extends from the first opening to the second opening enabling the needle to be inserted through the housing;
• aligning the needle with a needle guide extending into and along a portion of the pathway through the first and second openings, wherein the needle guide is aligned with a portion of a sensor wire, the portion of the sensor wire extending through the second opening and distally beyond the lower portion of the housing, wherein the needle guide includes a projection;
• and
• inserting the needle through the housing along the pathway, the needle guide preventing damage to the sensor wire as the needle is inserted through the housing.