Reprocessing and reuse of single-use electrosurgical pencils (EPs) is a diffused practice in countries with limited access to healthcare subvention system and in developing countries. However, safety and efficacy issues are associated to this practice, requiring specific methods for checking the reprocessed device before clinical re-use. This study aimed at defining a set of testing methods for assessing thermal and surface characteristics of reprocessed single-use EPs and evaluating the suitability of these techniques for revealing modifications between brand new and reprocessed single-use EPs. We reported a multi-technique approach based on optical and electron microscopy, X-rays spectroscopy and thermal analysis. The assessment of a total of 30 variables of interest on both brand new and reprocessed devices, allowed to identify the most informative ones. Seven of the evaluated variables were found to differentiate the reprocessed device from the new ones in a significant way. The presented methods deserve potential for tracking modifications during the device lifecycle.