A method for manufacturing a jaw member configured for use with an electrosurgical forceps, comprising: stamping a seal plate from sheet metal and forming a centrally-disposed structural insert portion and two sealing surface portions depending from the structural insert portion, the two sealing surface portions defining a gap therebetween positioning the seal plate into a mold cavity introducing an insulative substrate into the mold cavity positioning a knife channel mold into the mold cavity such that the knife channel is spaced from the seal plate, the knife channel configured for reciprocation of a knife blade therethrough allowing the insulative substrate to harden in the mold cavity to form a jaw housing with the seal plate secured thereto andremoving the jaw housing from the mold cavity to form the jaw member.
