Method of manufacturing a dry electrode

A method for manufacturing a dry electrode via a multi-roll calender system including providing the multi-roll calender system including a first, second, and third calendering rolls, each roll downstream from the next, where a first nip is formed between the first and second calendering rolls, and a second nip is formed between the second and third calendering rolls, rotating the first calendering roll at a first rotational velocity, rotating the second calendering roll at a second rotational velocity greater than the first rotational velocity, rotating the third calendering roll at a third rotational velocity greater than the second rotational velocity, delivering a first dry electrode material to the first nip to form a dry electrode film, delivering the dry electrode film to the second nip to form a tuned dry electrode film, and laminating the tuned dry electrode film to a current collector to form the dry electrode.