Jaw members and methods of manufacture

An end effector for use with a surgical stapling instrument comprising:

• an anvil assembly including:
• an anvil plate fabricated from a thermoplastic material and having a knife channel defined longitudinally therethrough, the anvil plate including:
• a first surface having a plurality of beads disposed along a periphery thereof;
• and
• a second surface opposite the first surface;
• and
• an anvil cover fabricated from a thermoplastic material and configured to be coupled to a distal end of the surgical stapling instrument, the anvil cover including a surface having at least one elongate surface feature disposed along a periphery thereof, wherein the plurality of beads of the anvil plate and the at least one elongate surface feature of the anvil cover are configured for abutting engagement upon assembly thereof;
• and
• a cartridge assembly, wherein at least one of the anvil assembly or the cartridge assembly is movable relative to the other between a spaced position and an approximated position to engage and staple tissue therebetween.

A method of manufacturing an anvil assembly of a surgical stapling instrument, the method comprising:

• providing an anvil plate fabricated from a thermoplastic material and having a knife channel defined longitudinally therethrough, the anvil plate including:
• a first surface having a plurality of beads disposed along a periphery thereof;
• and
• a second surface opposite the first surface;
• providing an anvil cover fabricated from a thermoplastic material and configured to be coupled to a distal end of a surgical stapling instrument, the anvil cover including a surface having at least one elongate surface feature disposed along a periphery thereof;
• and
• ultrasonically welding the anvil plate to the anvil cover at an interface between the plurality of beads of the anvil plate and the at least one elongate surface feature of the anvil cover.