An ultrasonic surgical device including an elongate waveguide having a longitudinal axis and a distal end, and a blade extending away from the distal end of the waveguide, the blade including a curved portion that has at least five faces extending lengthwise along at least a portion of the length of the blade. Each of the faces has a width that extends perpendicular to the longitudinal axis of the waveguide and a length that extends orthogonal to the width. Each of the faces is flat across its width and is either flat along its entire length or includes one or more curved segments along its length, with each of the curved segments of an individual face being curved in the same direction. A method of fabricating an ultrasonic surgical device is also provided.
