A method of making electrochemical sensors in which an electrolyte
material is cast into a tape. Prefabricated electrodes are then partially
embedded between two wet layers of the electrolyte tape to form a green
sensor, and the green sensor is then heated to sinter the electrolyte
tape around the electrodes. The resulting sensors can be used in
applications such as, but not limited to, combustion control,
environmental monitoring, and explosive detection. A electrochemical
sensor formed by the tape-casting method is also disclosed.