A process for merging webs for the production of an electrode assembly for a secondary battery, the process comprising: moving a first web of base material along a first web merge path, the first web of base material comprising (i) a population of first components for electrode sub-units, the first components delineated by corresponding weakened patterns (600, 604, 608), and (ii) a population of first conveying features (602, 612); moving a second web of base material along a second web merge path, the second web of base material comprising (iii) a population of second components for the electrode sub-units, the second components delineated by corresponding weakened patterns (600, 604, 608), and (iv) a population of second conveying features (602, 612); conveying a receiving member (1424, 2002) in a web merge direction adjacent the first web merge path and the second web merge path, the receiving member comprising a plurality of projections (1428, 2038) configured to engage with the first conveying features of the first web of base material and the second conveying features of the second web of base material; receiving, at a first web merge location, the first web of base material on the receiving member such that the conveying features of the first web of base material are engaged by at least some of the plurality of projections on the receiving member; and overlaying, at a second web merge location, the second web of base material on the first web of base material on the receiving member such that the first components are substantially aligned with the second components and the conveying features of the second web of base material are engaged by at least some of the plurality of projections on the receiving member, the second web merge location being spaced in a down web direction from the first web merge location, wherein the electrode sub-unit comprises components selected from the group consisting of an anode, a cathode, an anode current collector, a cathode current collector, and a separator. moving a first web of base material along a first web merge path, the first web of base material comprising (i) a population of first components for electrode sub-units, the first components delineated by corresponding weakened patterns (600, 604, 608), and (ii) a population of first conveying features (602, 612); moving a second web of base material along a second web merge path, the second web of base material comprising (iii) a population of second components for the electrode sub-units, the second components delineated by corresponding weakened patterns (600, 604, 608), and (iv) a population of second conveying features (602, 612); conveying a receiving member (1424, 2002) in a web merge direction adjacent the first web merge path and the second web merge path, the receiving member comprising a plurality of projections (1428, 2038) configured to engage with the first conveying features of the first web of base material and the second conveying features of the second web of base material; receiving, at a first web merge location, the first web of base material on the receiving member such that the conveying features of the first web of base material are engaged by at least some of the plurality of projections on the receiving member; and overlaying, at a second web merge location, the second web of base material on the first web of base material on the receiving member such that the first components are substantially aligned with the second components and the conveying features of the second web of base material are engaged by at least some of the plurality of projections on the receiving member, the second web merge location being spaced in a down web direction from the first web merge location, wherein the electrode sub-unit comprises components selected from the group consisting of an anode, a cathode, an anode current collector, a cathode current collector, and a separator.