The solvent evaporation of ibuprofen, Avicel, and Aerosil in selected ratios were evaluated for particle packing and rearrangement and drug release. Physicochemical characterization was carried out by using scanning electron microscopy (SEM), Fourier transform infrared spectroscopy (FTIR), and differential scanning calorimetry (DSC). Transitional tapping between primary rearrangement and secondary rearrangement was found to be 2030 taps with native ibuprofen powder and up to 45 taps with all formulated powders. Particle packing in the rearrangement stage was increased for all the formulations with respect to ibuprofen alone. Combination of Avicel and Aerosil brought about partial amorphization of the drug and improved wettability after solvent evaporation. Significantly improvement of packing of ibuprofen in rearrangement stage has been achieved by solvent evaporation of ibuprofen, Avicel, and Aerosil, which brought about improved release of drug from all formulated tablets.