Formation of an assemblage of electrically conductive components for a new electrosurgical pencil is disclosed, and assembly of those components in a method for automating the manufacture and combination of current carrying metal circuitry and operable switching components in “electrosurgical pencils” which supply current to an active terminal, for application of high frequency or high power electrical current to a surgical site, and control of such current through coaction of the elements of the switch. In manufacture, the design of the switch components allows start-to-finish automated assembly of the switch, whereby an array of identical multiple metal “frames” may be formed from a reel, then each frame separated and enclosed within molded plastic, and the resulting cabinet joined with a housing to create an inexpensive hand piece, for use with a high quality, reusable cable and plug assembly.
