Surgical instrument shafts and methods of manufacturing shafts for surgical instruments

A method of manufacturing a shaft of a surgical instrument, comprising:

• forming a proximal segment of the shaft;
• forming a distal segment of the shaft;
• forming an intermediate segment of the shaft;
• spin-welding the proximal segment of the shaft to a proximal end of the intermediate segment and the distal segment of the shaft to a distal end of the intermediate segment, the proximal and distal segments clocked to one another during spin-welding to ensure alignment of the proximal and distal segments in a pre-determined orientation relative to one another.

A method of manufacturing a shaft of a surgical instrument, comprising:

• stamping a proximal segment of the shaft to include at least one feature for operably engaging the shaft to a first component of the surgical instrument;
• stamping a distal segment of the shaft to include at least one feature for operably engaging the shaft to a second component of the surgical instrument;
• forming an intermediate segment of the shaft;
• cutting the intermediate segment to a pre-determined length;
• welding the proximal segment of the shaft to a proximal end of the intermediate segment;
• and
• welding the distal segment of the shaft to a distal end of the intermediate segment.