Effects of different mesh nebulizer sources on the dispersion of powder formulations produced with a new small-particle spray dryer

•Different mesh sources evaluated in a new small-particle spray dryer system.•Aerogen Solo and Aerogen Pro mesh sources performed the best.•Tested aerosolization from a new infant air-jet dry powder inhaler.•Mean fine particle fraction <5 µm in the range of 80.6–77.4%.•Greater than 40% of loaded dose delivered through preterm infant nose-throat model.