Method of forming suction instrument end and shaver instrument end

A method of manufacturing a medical instrument, the method comprising:

• engaging a die against a distal first end portion of a first tube while simultaneously moving the die relative to the distal first end portion of the first tube along a predetermined path thereby forming the distal first end portion with a predetermined shape;
• rotating the first tube relative to the die about a central longitudinal axis defined by the first tube;
• inserting a second tube into the first tube such that an inner radial surface of the distal first end portion engages an outer radial surface of the second tube;
• positioning a position sensor on a distal second end portion of the second tube;
• and
• welding the first tube to the second tube at an engagement therebetween to define a seam and assemble a shaft assembly thereby manufacturing at least a portion of the medical instrument.

A method of manufacturing a medical instrument, the medical instrument including a shaft assembly having a first tube, a second tube, and a position sensor, the first tube extending from a proximal first end portion to a distal first end portion, the second tube extending from a proximal second end portion to a distal second end portion, the method comprising:

• engaging a die against the distal first end portion of the first tube while simultaneously moving the die relative to the distal first end portion of the first tube along a predetermined path thereby forming the distal first end portion with a predetermined shape;
• inserting the second tube into the first tube such that an inner radial surface of the distal first end portion engages an outer radial surface of the second tube;
• positioning the position sensor on the distal second end portion of the second tube;
• and
• welding a distal end of the first tube to the distal end of the second tube at a location distal of the position sensor to define a single seam.