Abstract: A method of manufacturing and calibrating a sensor for an analyte monitoring device includes fabricating a plurality of sensors on a same substrate using substantially uniform processes for the entire substrate, separating each of the sensors from one another, organizing the separate sensors into at least one group, the at least one group including at least four of the separate sensors, testing a representative sensor from among the separate sensors in the at least one group to determine a first sensitivity while a plurality of the separate sensors in the at least one group remain untested, assembling one of the untested sensors with the analyte monitoring device, and providing the analyte monitoring device to a patient to monitor an analyte level in the patient. The first sensitivity is applied to the sensor assembled with the analyte monitoring device to facilitate monitoring of the analyte level in the patient.