The order in which the materials are fed into the extruder impacts the final product. In our experiments, the polymer powders are fed initially and go through the extruder in a continuous loop by means of a recirculation system. Once the polymers are molten, a premix of LFP and carbon powders is fed into the extruder. We simulate one passage of the materials until the extruder is filled and a steady-state at outlet is achieved. Therefore, the exact feed conditions of experiments cannot be reproduced. As an alternative, three different strategies are employed and analyzed (Fig ). Scenario A mimics a premix of LFP and BC, while the others consider the two powders as initially separate. B considers the two powders entering continuously one after the other, while in the feeding approach C, the inlets are located side by side. The 3D view of the extrusion process (Fig. ) clearly shows that scenario C has the lower mixing quality. In order to quantify the extent of mixing across the entire extruder, a Radial Distribution Function (RDF) can be estimated (right hand side of Fig. ). The RDF shows a larger peak at 10 µm corresponding to LFP-LFP contacts, in scenario C, indicating poor mixing. Due to the recirculation system used in our laboratory, this is not observed in our simulations, but it could appear in industrial extruders that commonly have a single passage. In that case, the scenario can be mitigated by a premixing of all the components as reported in at least one laboratory SF process. Scenarios A and B only slightly differ near the inlet region, though they quickly homogenize. Therefore, scenario C is the most critical for mixing quality during the simulated extrusion. This is the one chosen for the investigations in the subsequent sections, since in that case the simulations can provide more interesting information. Here the impact of the cohesion strength of LFP-BC and BC-BC on the electrode microstructure is evaluated. In simulations, this is achieved by changing the cohesion energy density (CED) of both interactions. The aim of this comparison is to indirectly elucidate the impact of polymer viscosity, which depends on the chosen extrusion temperature, that is not an obvious decision for experimentalists. Broadly speaking, an increase in viscosity can be represented by an increase in CED. One simulation with lower values of CED (case C) and one with higher values are carried out (case D). The specific CED values are presented in Table . Fig 4. shows snapshots of the extruder as if completely fills for both scenarios. As expected, case D exhibits a more compact flow. The difference is expected to accentuate for the case where the extruder has a continuous screw section, as in many real configurations. Furthermore, in the initial stages, the extrusion product shows poor mixing for case C, which is improved as the extruder fills.