Method of making an ultrasonic surgical instrument assembly

A method of making an ultrasonic surgical instrument assembly, the method comprising:

• providing a single piece carrier defining a lumen extending between proximal and distal regions of the single piece carrier and sized to receive a vibratory component of the ultrasonic surgical instrument, wherein an irrigation conduit separated from the lumen extends through the single piece carrier between the proximal and distal regions of the single piece carrier, and an outer surface of the single piece carrier defines a trench extending between the proximal and distal regions of the single piece carrier and defines at least one tab extending transversely over the trench;
• positioning a flexible conductor within the trench of the single piece carrier such that the flexible conductor runs under the at least one tab;
• and
• after positioning the flexible conductor, overmolding the single piece carrier to form an overmold assembly comprising a distal coupling feature for coupling the overmold assembly to a tip sleeve of the ultrasonic surgical instrument.