Described here are embodiments of processes and systems for the
continuous manufacturing of implantable continuous
analyte sensors. In some embodiments, a method is provided for sequentially advancing an elongated conductive body through a plurality of stations, each configured to treat the elongated conductive body. In some of these embodiments, one or more of the stations is configured to coat the elongated conductive body using a
meniscus coating process, whereby a solution formed of a
polymer and a
solvent is prepared, the solution is continuously circulated to provide a
meniscus on a top portion of a vessel holding the solution, and the elongated conductive body is advanced through the
meniscus. The method may also comprise the step of removing excess
coating material from the elongated conductive body by advancing the elongated conductive body through a die orifice. For example, a provided elongated conductive body 510 is advanced through a pre-
coating treatment
station 520, through a coating
station 530, through a thickness control
station 540, through a
drying or curing station 550, through a thickness
measurement station 560, and through a post-coating treatment station 570.