The influence of the solid content is investigated for cathodes with nickel cobalt manganese oxide (NCM) as an active material during the continuous dispersion in a twin‐screw extruder as well as during the coating and drying processes. Rheological and particle size distribution analyses are carried out to characterize the suspensions. Specifically, mechanical, structural, and electrochemical properties of the manufactured electrodes are determined. The presented results show that an increase in the solid content of the electrode suspension during the extrusion process results in a higher carbon black (CB) dispersion degree due to a higher energy input. At solid content above 80 wt%, delamination of conductive graphite and deposition of CB onto the active material occur. Furthermore, it is proved that within a range of 70–75 wt% solid content, the mechanical, conductive, and electrochemical performances can be enhanced.

In this work, detailed investigations concerning a continuous mixing process for lithium‐ion battery (LIB) electrodes are conducted. NCM622 (Li(Ni0.6Co0.2Mn0.2)O2) cathode electrodes are fabricated on behalf of a corotating twin screw extruder. Studies are performed concerning different material compositions and processing parameters, such as screw speed. Processing routes in relation to feeding of binder to the process zones as a dry powder or presolved in a liquid are examined. The produced cathode slurries are analyzed concerning rheological properties and dispersing degree, meaning particle size distribution. Subsequently, the coated electrodes are characterized regarding electrical conductivity, mechanical properties, and pore size distribution. Up to the present, the continuous mixing process of LIB electrodes is barely investigated. This study provides deep insight into the process–structure–property relations of the continuous mixing process.