The processing induced active particle assembly determines the internal microstructure and resultant performance of the electrode in a lithium-ion battery. A morphology-detailed mesoscale model has been developed to gain fundamental understanding of the influence of active particle morphology, size, volume fraction, solvent evaporation, and multi-phase (active particle, conductive additive, binder and solvent) interaction. Our results demonstrate that smaller isometric active particles tend to form favorable aggregation with conductive additive particles. Two regimes, namely spontaneous aggregation and evaporation induced aggregation, have been identified. Low solvent evaporation rate promotes spontaneous aggregation resulting in an enhanced interfacial area than that in evaporation-induced aggregation. The influence of active material morphology and volume fraction on conducting pathway formation has been conjectured.The need for the development of rechargeable lithium-ion batteries (LIBs), with improved performance, life and safety combined with reduced cost, for vehicle electrification is at the forefront of critical energy research. [1][2][3][4] In this regard, there has been significant advancement in nanomaterial development for improved performance. 5-8 Another important driver is the electrode processing which plays a critical role. 9,10 The processing conditions and concomitant physicochemical attributes are envisioned to pose an intimate bearing on the resultant electrode microstructures and ultimately on the performance.The processing of the multi-phase slurry, which consists of active particle, conductive additive, binder and solvent, determines the electrochemical properties and performance of the electrode. 11-17 In the electrode processing, it is necessary to make these components cooperate very well with each other. It is well known that the active material stores lithium ions, the conductive additive is employed to increase the electronic conductivity and the binder links the active material and the conductive additive together to form the robust network. 18 It is important to point out that the role of each component is not independent, and components can be affected by each other. For example, the active materials always suffer from poor electronic conductivity, and the aggregation of active material nanoparticles deteriorates the performance of the electrode because the electric conductivity is further lowered. [19][20][21] To avoid this problem, a proper processing can make conductive nanoparticles be coated on active nanoparticles and prevent the direct aggregation between active nanoparticles, so conductive additives fill the space between the active materials to form the continuum network for enhancing the electric conductivity. 22,23 Additionally, the high surface area of the nanostructured active material raises the risk of the capacity fading, because the solid electrolyte interface (SEI) forming on the active material consumes a lot of Li + ions supplied by the cathode, and the dissolu...