An electrode sensor involves a solid conductive polymeric substrate shaped as an electrode sensor or portion of an electrode sensor having a layer of silver-coated particles distributed on and embedded into a surface of the substrate. The electrode sensor is particularly useful for ECG electrodes and utilizes less silver without unduly sacrificing performance. A process for producing the electrode sensor involves distributing a layer of silver-coated particles on a surface of a solid conductive polymeric substrate shaped as an electrode sensor or portion of an electrode sensor and thermally embedding the silver-coated particles into the surface. The process is simpler and less costly than existing processes for producing electrode sensors.