A method of manufacturing an endodontic instrument using an electrochemical (ECG) grinding process. An instrument blank is formed from stock material, and an electric current is applied between an electrically conductive grinding wheel, acting as a cathode, and the instrument blank, acting as an anode. A continuous stream of electrolyte fluid, a conductive aqueous solution, is applied at an interface between the grinding wheel and the instrument blank, the electrolyte fluid having an associated volume and pressure. The instrument blank is advanced past the electrically conductive grinding wheel to remove material from the instrument blank to form at least one cutting flute. The electric current applied between the grinding wheel and the instrument blank is reduced, and the instrument blank is advanced past the grinding wheel again to form a finish surface, e.g., a sharp cutting edge, on the at least one cutting flute. The process may be repeated to form an endodontic instrument having a plurality of cutting flutes. The cutting flutes may be helically or non-helically shaped. The instrument blank is formed of an electrically conductive material, such as nickel titanium or stainless steel. In one variation, the electric current may be eliminated entirely during the final finishing pass. The volume and pressure of the electrolyte may be varied. Endodontic instruments formed by the method of the present invention are also disclosed.