Surgical forceps and method of manufacturing thereof

1. A method of manufacturing a jaw member of a surgical instrument, comprising:

forming a substrate via injection molding;

forming an electrically-conductive member on a surface of the substrate via vapor deposition; and

engaging the substrate to a jaw frame, the jaw frame defining a cavity for receiving the substrate.

2. The method according to claim 1 , wherein the vapor deposition includes physical vapor deposition.

3. The method according to claim 1 , wherein the vapor deposition includes chemical vapor deposition.

4. The method according to claim 1 , further comprising molding a wire to the substrate prior to forming the electrically-conductive member on the surface of the substrate.

5. The method according to claim 4 , wherein the electrically-conductive member is formed on the surface of the substrate such that the electrically-conductive member is in electrical communication with the wire.

6. The method according to claim 1 , wherein engaging the substrate to the jaw frame includes snap-fitting the substrate to the jaw frame.

7. A method of manufacturing a surgical instrument, comprising:

forming a first substrate of a first jaw member via injection molding of an electrically insulative material;

depositing a first electrically-conductive member on a first surface of the first substrate via vapor deposition;

engaging the first substrate within a cavity defined by a jaw frame of the first jaw member to secure the first substrate to the first jaw member;

depositing a second electrically-conductive member on a second surface of a second jaw member via vapor deposition; and

coupling the first jaw member to the second jaw member to permit movement of at least one of the first and second jaw members relative to the other between a spaced-apart position and an approximated position for grasping tissue between the jaw members, the first surface opposing the second surface.

8. The method according to claim 7 , wherein the vapor deposition includes physical vapor deposition.

9. The method according to claim 7 , wherein the vapor deposition includes chemical vapor deposition.

10. The method according to claim 7 , wherein engaging the first substrate within the cavity of the jaw frame of the first jaw member includes snap-fitting the substrate within the jaw frame.

11. The method according to claim 7 , wherein engaging the first substrate within the cavity of the jaw frame of the first jaw member includes friction-fitting the substrate within the jaw frame.

12. The method according to claim 7 , further comprising pivotably coupling a proximal flange of the first jaw member to a proximal flange of the second jaw member to permit movement of at least one of the jaw members relative to the other between the spaced-apart position and the approximated position.

13. The method according to claim 7 , further comprising molding a wire within the first jaw member such that the wire is disposed in electrical communication with the first electrically-conductive member for supplying energy to the first electrically-conductive member.

14. A method of manufacturing a jaw member of a surgical instrument, comprising:

injection molding a substrate of electrically insulative material; and

vapor depositing an electrically-conductive member on a surface of the substrate.

15. The method according to claim 14 , further comprising coupling a wire to the substrate prior to vapor depositing the electrically-conductive member thereon such that, upon depositing the electrically-conductive member on the surface of the substrate, the wire is electrically coupled to the electrically-conductive member for providing energy to the electrically-conductive member.