A process for the manufacture of small sensors with reproducible surfaces, including electrochemical sensors. One process includes forming channels in the surface of a substrate and disposing a conductive material in the channels to form an electrode. The conductive material can also be formed on the substrate by other impact and non-impact methods. In a preferred embodiment, the method includes the steps of providing a continuous substrate web, and disposing a pattern of a conductive material on the continuous substrate web to form one or more working electrodes and/or counter electrodes.
