Optical Sensor Element for Analyte Assay in a Biological Fluid, as Method and Manufacture Thereof

A method of fabricating optical wafers for biological fluid sensors, comprising:

• establishing a plurality of cutout apertures in a sheet of optically transparent polymer material to define respective tapered portions of the optical wafers and expose edges thereof;
• establishing a plurality of transverse lines in the sheet to define respective main portions of the optical wafers and partially expose edges thereof, the main portions being respectively merged with the tapered portions;
• separating the sheet along a plurality of longitudinal lines into a plurality of strips to expose respective tips in the tapered portions of the optical wafers;
• applying a texturing treatment to the tips exposed in the separating step to form a field of elongated projections in the tips;
• depositing a fluid slurry mixture of analyte-reactive reagent and light scattering particles within the field of elongated projections;
• and
• following the texturing treatment applying step and the fluid slurry mixture depositing step, separating the optical wafers from one another along the transverse lines.