Systems for manufacturing a working wire for a continuous biological sensor include an automated measurement system configured to measure, as an in-line process with a dipping station, a plurality of diameters along a length of a working wire. Systems also include a controller in communication with the automated measurement system, wherein the controller is configured to determine a thickness difference, the thickness difference being a difference between a thickness setpoint and an aggregate criteria for the plurality of diameters. The systems may include the dipping station, that is configured to hold a coating solution, and may include a robot positioned to move the fixture to the automated measurement system.