In a medium bowl, whisk together the vanilla protein powder, almond flour, and salt. This pre-mixing ensures the protein powder distributes evenly throughout the bars without clumping when you add the wet ingredients. I find whisking for about 30 seconds is all you need to break up any lumps in the protein powder.
Add the almond butter and honey to the dry ingredient mixture from Step 1, then stir vigorously until everything comes together into a thick, cohesive dough. The mixture will be dense and slightly sticky—this is exactly what you want. I always use super-fine almond flour because it creates a smoother, less grainy texture that binds beautifully with the wet ingredients.
Place a sheet of parchment paper on your work surface and transfer the dough mixture onto it. Using your hands or the back of a spoon, press and spread the mixture into an even layer about 1/2 inch thick. Once shaped, use a sharp knife to slice the slab into 8 large bars or 12 smaller bars, depending on your preference. Wipe your knife clean between cuts for cleaner edges.