Method of manufacturing a dry electrode

A method of manufacturing a dry electrode via a multi-roll calender system, comprising:

• providing the multi-roll calender system including a first calendering roll, a second calendering roll downstream from the first calendering roll and a third calendering roll downstream from the second calendering roll, wherein a first nip is formed between the first calendering roll and the second calendering roll, and a second nip is formed between the second calendering roll and the third calendering roll;
• rotating the first calendering roll at a first rotational velocity;
• rotating the second calendering roll at a second rotational velocity that is greater than the first rotational velocity;
• rotating the third calendering roll at a third rotational velocity that is greater than the second rotational velocity;
• delivering a first dry electrode material by the multi-roll calender system to the first nip to form a dry electrode film;
• delivering the dry electrode film by the multi-roll calender system to the second nip to form a first tuned dry electrode film;
• and
• laminating the first tuned dry electrode film to a current collector to form the dry electrode.