Laser patterning conductive vacuum deposited films for production of low cost/high throughput flexible electronic devices provides versatility, significantly increased development cycles and scalability. Using ablation by laser patterning for subtractive manufacturing allows scan rates of up to 8000 mm/s for high volume production of discrete devices. Performance can be optimized by adjusting device architecture or geometry which allows for real time alterations of the laser scanning pattern without cost impact of materials or time and materials costs for mask fabrication. Success of the laser patterning is directly impacted by surface roughness; the surface morphology effects the continuity and adhesion of successive sputtered thin film layers and their final performance. Tuning the surface roughness by laser patterning to control biological fluid flow on a device surface can be shown. Sensor response data shows comparisons of thermal and laser activated crystallization by lasers of vacuum deposited thin films. The ability to integrate laser technology with roll-to-roll technology with in situ quality control will provide low-cost production devices for biological analysis.