<p>Calendering is a critical step in the manufacturing process of lithium-ion batteries, but simulating this process presents challenges due to the binder, which bonds discrete particles to the continuous metal foil. In this study, we propose a numerical model to simulate the calendering process effectively. The model treats the metal foil as a continuum using the finite element method (FEM) and represents the active particles as discrete entities using the discrete element method (DEM). To account for the binder’s effect on the metal foil, a set of ghost particles is embedded within a narrow zone of the continuum, enabling volume coupling. A damage variable is introduced at the level of individual particles to assess the effects of the calendering process. Additionally, we present a comprehensive approach for calibrating material parameters through physical experiments. The model’s effectiveness is demonstrated through two examples, highlighting its ability to analyze key manufacturing parameters such as roller compression and curvature. This study provides a valuable tool for simulating the calendering process, capturing the essential role of the binder, and guiding the optimization of electrode manufacturing.</p>