Nasal dry powder vaccines may provide safe, effective, stable, and affordable alternatives to currently available influenza vaccines. It was proposed that maximal mucosal and systemic antibody production would be elicited by a whole inactivated influenza virus dry powder nasal vaccine formulation in response to increased local residence time. Full factorial designed experiments examining freezing rate, solute concentration, and annealing (freeze-drying) and solution feed rate, atomization airflow rate, and solute concentration (spray-freeze-drying (SFD)) were used to produce particles suitable for nasal delivery. Freeze-drying followed by milling and sieving produced heterogeneous-shaped particles below the targeted particle size, which weren't ideal for blending with mucoadhesive compounds (MA). Optimized SFD runs produced particles for human (D₅₀=38.5μm) and rat (D₅₀=26.9μm) delivery which were characterized for flow and thermal properties, surface area, true density, moisture content, and impact energy separation and demonstrated improved storage stability than liquid formulations. A modified cascade impactor was calibrated to characterize particles in the 10-20μm size range.