Abstract: A method of manufacturing a jaw member of an end effector assembly for use with an electrosurgical instrument is disclosed that includes the steps of providing an electrically conductive tissue engaging plate and a jaw support; covering one side of the electrically conductive tissue engaging plate with an electrically insulative, thermally non-degrading coating; placing and securing the electrically conductive tissue engaging plate 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 and the jaw support. Alternatively, the method includes the steps of: providing an electrically conductive tissue engaging plate and a jaw support; covering one side of the electrically conductive tissue engaging plate with an electrically insulative, thermally non-degrading coating; and securing the side of the electrically conductive tissue engaging plate onto the jaw support with an adhesive.