<p>The roll-to-roll (R2R) technique is instrumental in the continuous application of uniform coating layers on thin webs and has become a cornerstone in the mass production of Lithium-ion batteries. However, this process is susceptible to web elongation variations induced by numerous process variables, leading to crease formation. Such creases considerably compromise the efficiency of the final product, necessitating effective mitigation strategies. Contrary to previous studies that largely examined crease formation on bare substrates, our research addresses the more complex scenario of multi-strip coating, as encountered in real-world industrial applications. We developed a simulation model to accurately depict the intricate dynamics of crease formation during web transfer with multi-strip coating and validated it through experimental approaches. Uneven tension caused by specific coating patterns plays a pivotal role in initiating crease formation. Research has indicated that the gap between the coated and uncoated layers Limits the area where friction occurs, which directly applies tension to the coated layer only. This tension application mechanism was found to result in strain distribution and ultimately affect crease formation. Through a detailed analysis of crease severity, we optimized the geometric parameters of the electrodes, reducing crease formation by approximately 73%. This investigation not only sheds light on the way coating exacerbates crease formation but also provides a thorough examination of strategies to curtail defects in the battery production process. By understanding the underlying mechanisms of crease formation and introducing effective countermeasures, our study significantly enhances the R2R process for the mass production of lithium-ion batteries.</p> Graphical abstract <p></p>