TECHNOLOGY FOCUS - INORGANIC CHEMISTRY - Preferred Component: The composition further includes a catalyst comprising an oxide or nitride of iron (Fe), cobalt (Co), ruthenium (Ru), manganese (Mn), zinc (Zn), molybdenum (Mo), chromium (Cr), copper (Cu), vanadium (V), nickel (Ni), and/or rhodium (Rh). The catalyst further comprises a friction reducing agent. The particulate electrical conductor comprises carbon and/or elemental metal. The liquid comprises water. Preferred Composition: The catalyst comprises (wt.%) carbon black (80-99.9) and metal (0.1-20). It further comprises nitrogen (0.05-5). The solids comprise conductive particles (at least20). The composition comprises liquid (at least20). Preferred Material: The friction reducing agent is graphite, molybdenum disulfide, boron nitride, cadmium iodide, antimony thioantimonate, antimony trioxide (Sb2O3), and/or amino phosphates.    TECHNOLOGY FOCUS - POLYMERS - Preferred Component: The fibrillatable polymer comprises polytetrafluoroethylene or a copolymer. It further comprises a second polymer.    TECHNOLOGY FOCUS - ORGANIC CHEMISTRY - Preferred Material: The surfactant comprises polyoxyethylenated alkyl phenol and/or polyoxyethylene alcohol. Preferred Composition: The surfactant concentration in the liquid is at most4 wt.%.    TECHNOLOGY FOCUS - CHEMICAL ENGINEERING - Preferred Process: The electrode formation method further comprises extruding the electrode composition prior to calendering, drying the electrode sheet to form a gas permeable dried film having at most5 wt.% liquid, and attaching a current collector to the cathode composition. The mold is heated during the molding process. Preferred Parameter: The calendering is performed at 30-80 degrees Celsius. The mold is under vacuum when the electrode composition is placed within the mold. The electrode composition is evacuated at a pressure lower than atmospheric pressure.    TECHNOLOGY FOCUS - MECHANICAL ENGINEERING - Preferred Device: The calendering is performed with rollers or belts. The extruding is performed with a ram extruder. The calendering comprises passes through a calendering apparatus.    TECHNOLOGY FOCUS - METALLURGY - Preferred Material: The anode comprises zinc or its alloy. EXAMPLE - A zinc-air fuel cell was produced with electrode prepared using calendering of polytetrafluoroethylene (PTFE) with an aqueous liquid. The process involved preparing an active layer by mixing Tergitol surfactant solution (30g) and blended active layer mixture (15 g), and a backing layer by mixing the surfactant solution (21.5 g) and blended backing layer powder (15 g). The layers were co-laminated together along with a current collector to complete an electrode assembly.