This study deals with development of melt sonocrystallization technique for ibuprofen agglomerates and characterization of their physicochemical, micromeritic and compressional properties. Melt sonocrystallization process was developed for ibuprofen in which ibuprofen melt was poured in deionized water maintained at 25 degrees C and simultaneously subjected to ultrasonic energy. The agglomerates obtained were evaluated using Scanning electron microscopy (SEM), Differential scanning calorimetry (DSC), X-ray powder diffractometry (XRPD), Fourier transformed infrared spectroscopy (FTIR), intrinsic dissolution rate, BET analysis, solubility, image analysis, Heckel plot analysis and friability studies. The irregular agglomerates with porous surface were obtained. The agglomerates comprised of crystals having different crystal habits such as needles, plates, and some hollow tubes. Solubility, specific surface area and intrinsic dissolution rate increased with the treatment of ultrasonic energy. SEM and XRPD confirmed crystal habit changes. Improvement in compressional properties and reduction in sticking was observed due to the change in crystal habit. Crystal habit changes and lattice defects during processing have caused favorable changes in the physicochemical and compressional properties of the drug.