Method of making an electrochemical sensor

Abstract

An electrochemical sensor with a capillary channel is formed by placing a sacrificial insert on a sensor base and applying casting material. After a casting material is cured, the sacrificial is removed leaving a capillary channel in the sensor. The insert may be removed by a tool including a clamp for clamping and holding the insert stationary and a sliding block to which the sensor is secured.

1 . A method of making a capillary channel in an electrochemical biosensor, the method comprising the acts of: 
 forming a base member including an active area with at least one electrode;    placing a sacrificial insert on said base member;    applying casting material over said sacrificial insert and on said base member; and    mechanically removing said sacrificial insert leaving a capillary channel in said casting material.    
   
   
       2 . The method of  claim 1  comprising providing a reagent in said active area.  
   
   
       3 . The method of  claim 1  wherein the at least one electrode is a plurality of electrodes and wherein the plurality of electrodes is in said capillary channel.  
   
   
       4 . The method of  claim 1  comprising curing said casting material prior to removing said sacrificial insert.  
   
   
       5 . (canceled)  
   
   
       6 . (canceled)  
   
   
       7 . (canceled)  
   
   
       8 . The method of  claim 1  wherein said capillary channel has a height of about 0.005 inch.  
   
   
       9 . The method of  claim 1  further including screen-printing said active area.