Abstract: Electrode compositions can be formed comprising a fibrillatable polymer, a particulate electrical conductor a surfactant and a liquid. Corresponding methods apply shear to fibrillate the polymer, in which the surfactant facilitates the processing such that the resulting electrodes have desirable properties. The shear can be applied in an extrusion process and/or calendering process. These improved processing approaches can be used to form large commercial electrodes with a high degree of thickness uniformity. In some embodiments, the electrode compositions comprise a fibrillatable polymer, a particulate electrical conductor and a non-carbon friction reducing agent within a gas permeable structure. Molding processes can be used for forming the electrodes.