A method of forming batteries includes feeding a foil through a coating machine. The movement of the foil defines a foil direction. The method applies a first coating band and a second coating band to the foil. The second coating band is spaced from the first coating band by a first tab gap. The foil is cut substantially perpendicular to the foil direction to separate a first coated blank. The first coated blank is cut separate the first coating band and a first portion of the first tab gap, and to separate the second coating band and a second portion of the first tab gap. A first electrode is formed from the first coating band and the first portion of the first tab gap, and a second electrode is formed from the second coating band and the second portion of the first tab gap.