Manufacturing electrosurgical instruments

A jaw member for an electrosurgical instrument is manufactured by providing a jaw housing (1) having a longitudinal jaw section (2), and an electrically conductive plate (11) including one or more passages (14) therein. The electrically conductive plate is disposed on the jaw section of the jaw housing, and placed into a mold (15). A flowable insulating material (18) is injected into the mold to secure the electrically conductive plate to the jaw housing, such that the flowable material (18) flows through the one or more passages (14) to form one or more stop members (21) that project a predetermined distance from the electrically conductive plate.