The ingredients of a simulant formulation including alumina nanoparticles were processed with a solvent mixture of ethanol and ethyl acetate in the 7.5 mm L/D=15 mm fully intermeshing co-rotating twin screw extruderJ. The nanoaluminized formulation was extrudable and generated little torque and negligible pressures in the die or the extruder. During molding powder preparation, upon extrusion and prior to the characterization of the dynamic properties of the extruded formulation, the solvent concentrations of the formulation samples were measured by gravimetric analysis. The dynamic properties of the molding powder and the twin-screw extruded nanoaluminized formulation were characterized using the ARES rotational rheometer.