Method for manufacturing an end effector assembly

A method for manufacturing a jaw member of an end effector assembly for use with an electrosurgical instrument, the method comprising the steps of:

• providing an electrically conductive tissue engaging plate, said electrically conductive tissue engaging plate having vertically-extending edges extending about a periphery and along a length thereof of said electrically conductive plate, and a jaw support;
• covering one side of the electrically conductive tissue engaging plate and said vertically-extending edges with an electrically insulative, thermally non-degrading coating;
• placing the electrically conductive tissue engaging plate, the electrically insulative, thermally non-degrading coating, and the jaw support into a jaw mold;
• and
• introducing a liquid substance into the jaw mold and allowing the liquid substance to cure around the electrically conductive tissue engaging plate, the electrically insulative, thermally non-degrading coating and the jaw support to form an overmolding around the electrically conductive tissue engaging plate, around the electrically insulative, thermally non-degrading coating, and around the jaw support.