Surgical Instrument Shafts and Methods of Manufacturing Shafts for Surgical Instruments

A surgical instrument, including:

• a metal outer sleeve defining an internal passageway;
• a plastic inner shaft disposed within the outer sleeve to substantially fill the internal passageway, the shaft formed via molding and including at least one lumen extending at least partially therethrough, the at least one lumen defining a cross-sectional shape different from the cross-sectional shape of the internal passageway of the outer sleeve;
• an end effector assembly coupled to a distal end of the inner shaft;
• and
• at least one component coupled to the end effector assembly and extending proximally at least partially through the at least one lumen of the inner shaft.