Positive electrodes for plastic Li-ion batteries were prepared with several PVDF–HFP based binders, using various types and amounts of plasticizers, under a variety of processing conditions. By varying temperature and pressure of the electrode densification step, electrodes exhibiting a wide range of thickness and porosity were prepared. In addition, the effect of plasticizer removal by solvent extraction or evaporation was investigated. The effect of these parameters on the discharge rate capability and the energy density of these electrodes was quantified, and the results were implemented in the simplified plastic battery manufacturing process that resulted in improved battery performance.