Calendering is an essential step to densify the porous structure of lithium-ion battery electrodes, enhancing the energy density and mechanical properties. This process involves mechanical interactions among particles and between particles and current collector. Microscopic damage from particle embedding into the current collector surface reduces the tensile strength, causing electrode fractures during calendering. This study investigated the evolution of electrode morphology, porosity, and specific surface area under incremental calendering. Additionally, the effects of active particle morphology and structural densification on electrode conductivity were analyzed. Microscale scratch and peel tests were conducted to determine the relationship between the line load and coating cohesion to analyzing current collector fracture behavior. The results show that an increased line load boosts coating cohesion but increases the susceptibility of the current collector to fracturing, ultimately reducing electrode fracture energy. This study elucidates the deformation and fracture mechanisms under the combined effects of coating densification and microscopic damage to the current collector during the calendering process, providing insights for optimizing process parameters and coordinated control. Display omitted •The pore structure evolution of electrode during the calendering process has been defined.•The effect of the electrode structure on the electronic conductivity has been examined.•The fracture mechanism in the electrode calendering process has been detailed at a microscopic level.