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Here we integrate device and formulation characterization, theoretical analysis, numerical simulations, and machine learning to map airflow\u2013particle dynamics across DPIs. Device geometry sets internal flow fields, which modulate drag, swirl, and impact, thereby mobilizing powders and driving transient deagglomeration. For fine particle\u2010dominated DPI formulations, gravity acting on fines is negligible, whereas adhesive force dominates in static powder beds and decays as agglomerates break up, driven by aerodynamic interactions and particle impacts. Highly adhesive carrier\u2010free agglomerates disperse via strong swirl and frequent particle\u2013wall impacts, while carrier\u2010based blends with moderate adhesion rely on aerodynamic drag and high\u2010energy carrier impacts. Further assisted by machine learning, we identify flow rate, drag, and particle\u2013wall impacts as primary contributors to dispersion, whereas particle\u2013particle impacts are a principal inhibitor. This integrated work reveals how devices and formulations shape airflow\u2013particle dynamics and aerodynamic performance, providing mechanism\u2010based guidance for next\u2010generation DPI design.<\/jats:p>","DOI":"10.1002\/smll.75610","type":"journal-article","created":{"date-parts":[[2026,9,3]],"date-time":"2026-09-03T06:55:02Z","timestamp":1788418502000},"update-policy":"https:\/\/doi.org\/10.1002\/crossmark_policy","source":"Crossref","is-referenced-by-count":0,"title":["Revealing Airflow\u2013Particle Dynamics in Dry Powder Inhalers"],"prefix":"10.1002","author":[{"ORCID":"https:\/\/orcid.org\/0000-0002-3796-9048","authenticated-orcid":false,"given":"Jiale","family":"Chen","sequence":"first","affiliation":[{"name":"Nottingham Ningbo China Beacons of Excellence Research and Innovation Institute University of Nottingham Ningbo China  Ningbo People's Republic of China"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Ziyi","family":"Fan","sequence":"additional","affiliation":[{"name":"Department of Biomedical Engineering University of Western Ontario  London Ontario Canada"},{"name":"Eastern Institute of Technology  Ningbo People's Republic of China"},{"name":"Ningbo Key Laboratory of Inhalation Drug Development and Advanced Delivery Eastern Institute of Technology  Ningbo People's Republic of China"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-6905-8484","authenticated-orcid":false,"given":"Qingliang","family":"Yang","sequence":"additional","affiliation":[{"name":"College of Pharmaceutical Science Research Institute of Pharmaceutical Particle Technology Zhejiang University of Technology  Hangzhou People's Republic of China"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0003-2434-1259","authenticated-orcid":false,"given":"Yuanyuan","family":"Shao","sequence":"additional","affiliation":[{"name":"Nottingham Ningbo China Beacons of Excellence Research and Innovation Institute University of Nottingham Ningbo China  Ningbo People's Republic of China"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-6528-2083","authenticated-orcid":false,"given":"Dongbing","family":"Li","sequence":"additional","affiliation":[{"name":"Nottingham Ningbo China Beacons of Excellence Research and Innovation Institute University of Nottingham Ningbo China  Ningbo People's Republic of China"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-2597-2936","authenticated-orcid":false,"given":"Xiaoyang","family":"Wei","sequence":"additional","affiliation":[{"name":"Nottingham Ningbo China Beacons of Excellence Research and Innovation Institute University of Nottingham Ningbo China  Ningbo People's Republic of China"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Xiang","family":"Luo","sequence":"additional","affiliation":[{"name":"Department of Chemical and Environmental Engineering University of Nottingham Ningbo China  Ningbo People's Republic of China"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Kaiqi","family":"Shi","sequence":"additional","affiliation":[{"name":"Ningbo Key Laboratory of Inhalation Drug Development and Advanced Delivery Eastern Institute of Technology  Ningbo People's Republic of China"},{"name":"Suzhou Inhal Pharma Co., Ltd.  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