Abstract: A jaw member for a surgical instrument includes a jaw housing and a first electrically conductive material deposited atop the jaw housing. An electrical wire is operably associated with the jaw housing and includes an exposed, electrically conductive tip. The exposed, electrically conductive tip is disposed atop the first electrically conductive material. A second electrically conductive material is deposited atop the exposed, electrically conductive tip to secure the exposed, electrically conductive tip in electrical contact with the first electrically conductive material.

Abstract: A method of manufacturing a thermal cutting element for a surgical instrument includes manufacturing a substrate, coating at least a portion of the substrate via Plasma Electrolytic Oxidation (PEO), and disposing a heating element on at least a portion of the PEO-coated substrate. The method may further include attaching the thermal cutting element to a jaw member of a surgical instrument.

Abstract: A method of manufacturing a thermal cutting element for a surgical instrument includes manufacturing a substrate, coating at least a portion of the substrate via Plasma Electrolytic Oxidation (PEO), and disposing a heating element on at least a portion of the PEO-coated substrate. The method may further include attaching the thermal cutting element to a jaw member of a surgical instrument.

Abstract: A thermal cutting element for a surgical instrument includes a substrate, a Plasma Electrolytic Oxidation (PEO) coating disposed on the substrate, and a heating element disposed on the PEO coating and including first and second end portions adapted to connect to different potentials of electrical energy to heat the heating element. A jaw member of a surgical instrument includes a structural frame including a proximal flange portion and a distal body portion, a jaw housing surrounding the distal body portion of the structural frame, a tissue-treating plate disposed atop the jaw housing and defining a longitudinal slot therethrough along at least a portion of a length thereof, and the thermal cutting element disposed within the longitudinal slot.