A manufacturing process of an end effector assembly for use with an instrument for sealing and cutting vessels and/or tissue, comprising: providing an end effector assembly comprising: a pair of opposing first and second jaw members (3510, 3710) at least one of which is movable relative to the other from a first spaced apart position to a second position for grasping tissue therebetween; each jaw member including an electrically conductive tissue sealing surface (3591, 3791) connectable to an electrosurgical energy source; a first of the jaw members including an electrically conductive cutting element (3527, 3727) disposed within an overmolded insulator (3597, 3797) defined in the jaw member; and the first jaw member including a rigid structural support which is configured to support the electrically conductive tissue sealing surface and includes perforations through which an overmolded insulative material flows through the rigid structural support during the manufacturing process, the sealing surface (3591, 3791) being surrounded by the overmolded insulator (3597, 3797), further comprising forming the cutting element (3527, 3727) raised above the sealing surface with multiple thin supports utilized to hold the cutting element in place and lancing out after the molding step the thin supports to ensure electrical insulation. providing an end effector assembly comprising: a pair of opposing first and second jaw members (3510, 3710) at least one of which is movable relative to the other from a first spaced apart position to a second position for grasping tissue therebetween; each jaw member including an electrically conductive tissue sealing surface (3591, 3791) connectable to an electrosurgical energy source; a first of the jaw members including an electrically conductive cutting element (3527, 3727) disposed within an overmolded insulator (3597, 3797) defined in the jaw member; and the first jaw member including a rigid structural support which is configured to support the electrically conductive tissue sealing surface and includes perforations through which an overmolded insulative material flows through the rigid structural support during the manufacturing process, the sealing surface (3591, 3791) being surrounded by the overmolded insulator (3597, 3797), further comprising forming the cutting element (3527, 3727) raised above the sealing surface with multiple thin supports utilized to hold the cutting element in place and lancing out after the molding step the thin supports to ensure electrical insulation. a pair of opposing first and second jaw members (3510, 3710) at least one of which is movable relative to the other from a first spaced apart position to a second position for grasping tissue therebetween; each jaw member including an electrically conductive tissue sealing surface (3591, 3791) connectable to an electrosurgical energy source; a first of the jaw members including an electrically conductive cutting element (3527, 3727) disposed within an overmolded insulator (3597, 3797) defined in the jaw member; and the first jaw member including a rigid structural support which is configured to support the electrically conductive tissue sealing surface and includes perforations through which an overmolded insulative material flows through the rigid structural support during the manufacturing process, the sealing surface (3591, 3791) being surrounded by the overmolded insulator (3597, 3797), further comprising forming the cutting element (3527, 3727) raised above the sealing surface with multiple thin supports utilized to hold the cutting element in place and lancing out after the molding step the thin supports to ensure electrical insulation.