A novel sub-miniature double-focusing sector-field mass spectrometer has been fabricated at the University of Minnesota using a combination of conventional machining methods and thin film patterning techniques typically used in the sensor technology industry. Its design is based on the mass separation capabilities of a 90°cylindrical crossed electric and magnetic sector-field analyzer with a 2-cm radius, which under proper conditions is able to effectively cancel the angular and chromatic dispersion of the ion beam, thus improving the resolving power of the instrument. Simulations using finite element analysis and computer modeling were employed to verify and optimize the performance of the proposed instrument before and during its fabrication. The prototype was able to attain a resolving power of 106 full-width at half-maximum (FWHM), a detection limit close to 10 parts per million, a dynamic range of 5 orders of magnitude and a mass range up to 103 Da. Its overall size, including the magnet assembly, is 3.5 cm wide, 6 cm long and 7.5 cm tall, it weighs 0.8 kg, and its power consumption was measured to be 2.5 W. The performance of the instrument was found to be comparable to that of commercial residual gas analyzers, at a fraction of the cost. All these characteristics make this miniature mass spectrometer suitable for portable and low-cost analytical instrumentation. A mong all the possible analytical instruments, few are more powerful and have a wider range of applications than mass spectrometers. Despite all their capabilities, traditional mass spectrometers do have several limitations. The major disadvantage of mass spectrometry as an analytical technique is the complexity of the instrumentation required and its associated cost. Although some special-purpose mass spectrometers are available with prices in the $5,000 range, as in the case of Residual Gas Analyzers (RGA), the typical cost of a general-purpose analytical mass spectrometer is $25,000 to $150,000 in the case of very high resolution instruments. The components, such as sample inlet, ion source, mass analyzer, detector housing, and vacuum envelope are typically manufactured by conventional machining techniques, assembled and aligned manually, and finally each one is individually tuned and calibrated to meet the manufacturer's product specification. Due to the number of independent pieces and the elaborate geometry of a typical instrument, the manufacturing process is not compatible with mass production techniques. Also, commercially available instruments require high vacuum systems to operate, and usually have high power requirements. Such requirements hinder the use of this powerful technique in applications that require a reliable, low-cost, small and portable analytical sensor, such as environmental sampling in situ.We began this research project with the belief that the complexity, and hence the cost of analytical mass spectrometry, can be drastically reduced, to permit this powerful technique to be used in applications where it has previously...