Abstract: A method of making a return pad for an electrosurgical system comprises the following steps. A first step includes die cutting an electrically conductive foil on a backing using a rotary press to create a foil blank. A second step includes peeling the conductive foil from around the blank, and leaving the blank on its backing. A third step includes layering electrically conductive gel together with the die cut foil to form a layered sheet. A fourth step includes blanking the return pad from the layered sheet using a rotary die. The rotary die has cutting edges and a die packing material adjacent to at least a portion of the edges. The die packing material compresses the gel prior to cutting. The compression is preferably sufficient to cause elastic deformation in the gel so that the gel retracts after being cut. The retraction of the gel leaves a border around the edge of the pad. The border region helps prevent the possibility of the gel coming into electrical contact with an unintended object.