Thermal cutting surgical instruments incorporate a blade incorporating a first substrate of high thermal conductivity material in the heated portion of the blade and a support and, the first substrate of high thermal conductivity material joined to a second substrate of low thermal conductivity material in the support region of the blade; an electrically insulative dielectric layer disposed on the first surface of the first substrate and on the first surface of second substrate; an electrically resistive heating element disposed on the electrically insulative dielectric; electrically conductive power leads and electrically conductive sense leads disposed on the electrically insulative dielectric layer and that are in electrical communication with the electrically resistive heating element; and an electrically insulative dielectric overcoat layer disposed on the electrically resistive heating element and on the distal portion of the electrically conductive power leads and electrically conductive sense leads.